HyperWorks 14.

0
HyperForm Tutorials

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Altair® HyperWorks®
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 HyperForm 14.0 Tutorials

HyperForm
...........................................................................................................................................
Tutorials 1
HF-0010: Introduction to HF Macros
............................................................................................................................................... 3
HF-0100: General Introduction
............................................................................................................................................... 9
RADIOSS One Step Tutorials
............................................................................................................................................... 27
HF-0150: Quick Setup
................................................................................................................................... 28
HF-0200: Geometry Cleanup
................................................................................................................................... 40
HF-0300: Automeshing
................................................................................................................................... 55
HF-0400: Mesh Quality
................................................................................................................................... 70
HF-0500: Model Preparation - Undercut Check and Autotipping
................................................................................................................................... 78
HF-1000: One-Step Stamping Simulation
................................................................................................................................... 82
HF-1010: Increasing Blankholder Pressures
................................................................................................................................... 92
HF-1020: Applying Drawbeads and Performing Circle Grid Analysis
................................................................................................................................... 95
HF-1030: Transferring Forming Results to Crash Analysis
................................................................................................................................... 101
HF-1040: Laser Weld
................................................................................................................................... 108
HF-1050: Trim Line Layout
................................................................................................................................... 112
Die Module Tutorials
............................................................................................................................................... 117
HF-2005: Basic Addendum Creation Using Die Process
................................................................................................................................... 118
HF-2010: Basic Addendum Creation with the Die Process
................................................................................................................................... 123
HF-2020: Creating a Parametric Addendum
................................................................................................................................... 128
HF-2030: Modifying a Parametric Addendum
................................................................................................................................... 146
HF-2040: Parameterization of External Binder and Addendum Section Using Section Editor
................................................................................................................................... 156
RADIOSS Incremental Tutorials
............................................................................................................................................... 165
HF-3000: Introduction to Incremental_RADIOSS and Incremental_LS-Dyna
................................................................................................................................... 166
HF-3000: Auto Process
................................................................................................................................... 173
HF-3010: User Process
................................................................................................................................... 187
HF-3020: Setting Up a Multistage Simulation with the User Process
................................................................................................................................... 198
HF-3030: Post Processing Forming Results in HyperView
................................................................................................................................... 204
HF-3010: Simple Draw Forming
................................................................................................................................... 214
HF-3020: Combined Binderwrap and Draw Forming Analysis
................................................................................................................................... 223
HF-3030: Drawbead
................................................................................................................................... 232
HF-3040: Redraw Forming Analysis from the User Process
................................................................................................................................... 239
HF-3050: Gravity
................................................................................................................................... 240
HF-3060: Trimming
................................................................................................................................... 242
HF-3070: Springback
................................................................................................................................... 244
HF-3080: Hot Stamping
................................................................................................................................... 245
HF-3090: Setting Up a Composite Forming Simulation
................................................................................................................................... 251
HF-3100: Post Processing Composite Forming Results in HyperView
................................................................................................................................... 253

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 HF-3110: Blank Optimizer
................................................................................................................................... 259
HF-3110: HydroForming
................................................................................................................................... 265
HF-3120: Tube Bending
................................................................................................................................... 273
HF-3130: Blank Shape Predictor
................................................................................................................................... 279
Optimization Tutorials
............................................................................................................................................... 285
HF-4010: Mesh Morphing
................................................................................................................................... 286
HF-4020: Optimization Using RADIOSS One Step
................................................................................................................................... 293
HF-4040: Process and Shape Optimization Using Incremental RADIOSS
................................................................................................................................... 300
Result Mapping Tutorials
............................................................................................................................................... 305
HF-5000: Using Result Mapper in HyperCrash
................................................................................................................................... 306
HF-5100: Result Mapping Using Process Manager
................................................................................................................................... 314
HF-6000: Die Structure Optimization
............................................................................................................................................... 323
HF-0010:
...........................................................................................................................................
Introduction to HyperBlank Macros 329

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HyperForm Tutorials

Introductory
HF-0010: Introduction to HF Macros
HF-0100: General Introduction and Functions

RADIOSS One Step

HF-0150: Quick Setup
HF-0200: Geometry Cleanup
HF-0300: Automeshing
HF-0400: Mesh Quality
HF-0500: Model Preparation - Undercut Check and Autotipping
HF-1000: One Step Stamping Simulation
HF-1010: Increasing Blankholder Pressures
HF-1020: Applying Drawbeads to a Model
HF-1030: Transferring Forming Results to Crash Analysis
HF-1040: Laser Weld
HF-1050: Trim Line Layout

Die Module
HF-2010: Basic Addendum Creation with the Die Process

Incremental Analysis
HF-3000: Auto Process
HF-3010: User Process
HF-3020: Setting Up a Multistage Simulation with the User Process
HF-3030: Post Processing Forming Results in HyperView
HF-3040: Redraw Forming Analysis from the User Process
HF-3050: Gravity
HF-3060: Trimming
HF-3070: Springback
HF-3080: Hot Stamping
HF-3090: Setting Up a Composite Forming Simulation
HF-3100: Post Processing Composite Forming Results in HyperView
HF-3110: HydroForming

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HF-3120: Tube Bending
HF-3130: Blank Shape Predictor

Optimization Study
HF-4010: Mesh Morphing
HF-4020: Optimization Using RADIOSS One Step
HF-4040: Process and Shape Optimization Using RADIOSS Incremental

Result Mapping
HF-5000: Using Result Mapper in HyperCrash

Die Structure Optimization

HF-6000: Die Structure Optimization

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HF-0010: Introduction to HF Macros

Radioss One Step Process Macros

From the menu bar, select Preferences > User Profile >Radioss_One_Step. The interface includes a
browser with a One Step tab:

Select the Utility tab. All the Radioss One Step macros are located on this page. These macros enable
you to quickly set up an analysis for a One Step simulation. The Radioss One Step macros are divided
into the following three sections.

Section Description

Model Lets you import, cleanup, and mesh the model.

Setup Lets you setup the model for simulation using Radioss
One Step.

Results Lets you post-process after the analysis is finished

running.

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Radioss One Step Utility menu

Incremental Process Macros

The following image shows the Utility Menu of the HyperForm interface with Incremental_Radioss and
Incremental_LsDyna user profile:

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Incremental_Radioss Utility Menu Incremental LS-DYNA Utility Menu

All of the macros are located in the RADIOSS or LS-DYNA page of the macro area. The incremental
process macros help you easily setup different application types. The following application types are
available under Application:
Form - 1st forming operation setup.
Bend - Tube bending setup.
Hydro - Hydroforming setup.
Blank Opti - Blank Optimizer
TL Opti - Trim Line Optimizer
Die Compensation - Die Compensation macro
Multi - 2nd or nth forming operation setup.

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 Trim - Trimming operation setup.
Coarse - Coarsening of blank mesh setup.
Sprbk - Springback setup.
Grav - Gravity setup.
Depending on the application type chosen, the setup process contains different macros. The
organization of the buttons within the Utility Menu is top-down, guiding you through each step of the
specific application type.
The following image shows the options available in the Incremental_LS-DYNA Utility Menu for the Multi
application.

Further explanation of each application type is provided in the subsequent tutorials.

For information about specific macros that are available, see the online help.

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HF-0100: General Introduction

HyperForm, a subset of Manufacturing Solutions, is a finite element based pre- and post-processor for
sheet metal forming. It combines an extremely fast one-step solver and incremental forming solution
using RADIOSS as the solver. It also integrates well with the LS-DYNA solver for incremental forming
simulation. With the customized geometry manipulation and mesh generation capabilities, HyperForm
enables you to build metal forming related finite element models, view their results, and perform data
analysis.
HyperForm integrates the functionality of HyperMesh and provides engineers at any stage of product
design with quick, valuable, reliable information, reducing the overall product cycle. HyperForm's die
module enables engineers to create and analyze conceptual die designs in order to generate an
optimized die. Die concepts can then be read into any CAD system as a starting block for the actual die
build. Integrated with HyperView, HyperForm can export data in the .h3d format allowing results to be
visualized using HyperView Player with any web browser.
This tutorial introduces HyperForm, as well as many basic concepts and tasks that are needed to get
started with HyperForm, and which serve as pre-requisites for most other HyperForm tutorials. In this
tutorial, you will be introduced to HyperForm from the one-step analysis point of view. The HyperForm
interface for incremental analysis will be described in later tutorials.
This tutorial covers:
Session 1: Fundamental HyperForm user interface
o User Profiles
o Graphics Area
o Using the mouse
o Tool bar menu
o Main menu
o Toggles and switches
o Utility menu
o The pull-down menus
Session 2: Using the online help
Session 3: File input and output
Session 4: The concept of collector
Session 5: Secondary menus
o Menu items
o Entity selector
o Direction selector
o Input fields
o Pop-up menus
o Function buttons

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 Session 6: Default HyperForm files

Exercises:
Three exercises are provided in this chapter:
Exercise 1: Opening a database file and using the tool bar
Exercise 2: Understanding Collectors and using online help
Exercise 3: Translating elements

Session 1: Fundamental HyperForm user interface

The HyperForm window consists of these main areas: the graphics area, the User Process tab, the
header bar, the main menu, Utility Menu, and the drop-down menu. You can access secondary menus
either through their main panel or by using keyboard function keys.

User profiles

The HyperForm user interface includes the following analysis configurations:

RADIOSS One Step: Setup, run, and review of a one-step analysis
Incremental_RADIOSS: Setup and run an incremental analysis using RADIOSS Solver
Die Module: Create and edit binders and addendums
Incremental_LS-DYNA: Setup and run an incremental analysis using the LS-DYNA solver
After starting HyperForm, the following dialog appears.

In the Application: field, select Manufacturing Solutions and then select one of the modules -

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RADIOSS One Step, Incremental_RADIOSS, Incremental_LS-DYNA, or Die Module - before
performing any further operations.
The selected configuration can include loading a specific template, loading a specific Utility menu,
renaming panels, removing unused panels or subpanels, and removing, moving, or renaming panel
options. The selected configuration can change the appearance of a panel, but they do not affect the
internal behavior of each function.

Graphics Area

The graphics area displays geometry, models, and XY plots.

Status Bar

The status bar is located at the bottom of the HyperForm window, just below the user profile switches
on the Utility menu. It displays the name of the current panel and user profile, and model status
information. Messages also appear on the message bar, temporarily overriding the title and status
information.

Using the Mouse

The mouse attached to your system is integral to HyperForm and can be used in almost every aspect of
user input. A two- or three-button mouse can be used with HyperForm.
The mouse buttons have these functions:

Left mouse button Performs selection operations.

Right mouse button De-selects entities in the graphics

area. Aborts graphics operations.

Middle mouse button In the rotate (r) and arc dynamic

motion (a) modes, selects a new
center of rotation when you pick a
node in the model.

CTRL + left mouse Dynamically rotates the model

button

CTRL + the middle Zooms into an area of the model

mouse button

CTRL + the right Pans the model

mouse button

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Toolbars

Collectors toolbar

Visualization toolbar

Display toolbar

The toolbars enable you to manipulate the view of the model, control which collectors are displayed in
the graphics area, set global modeling parameters, and edit solver-specific data.

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The functions of some of the toolbar menu icons are described below:

Panel Icon Description

Files Load, save, or import files.

Card edit Edit solver-specific data in card format

Wireframe Draws model geometry as a wire-frame

Elements

Shaded Draws model geometry in shaded mode

Elements &
Mesh Lines

Wireframe Draws model geometry as a wire-frame. Click the downward arrow

geometry to choose between excluding and including surface lines.

Shaded Draws model geometry in shaded mode. Click the downward

Geometry & arrow for options: with edges or without them.
Surface Edges

Visualization Show or hide different types of topology, connector, or morphing

entities. A sub-menu is enabled when this panel is selected.

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The following viewing icons are available:

Item Icon Description

Previous View Returns to the previous view

Fit Model Resizes the model view to fit the model to the graphics area

Modal Zoom Circle zoom (left-click) / Dynamic zoom (right-click).

Left-clicking activates the circle zoom feature. Circle zoom
deactivates after zooming once, or when you click either button
while the pointer is in the graphics area.
Right-clicking activates the dynamic zoom feature. Once active,
right-click and drag in the graphics area to zoom in/out. Left-click
to deactivate.

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Incremental Zoom incrementally; left-click to zoom in, right-click to zoom out
Zoom

Rotate Mode Rotate modes: this functions in one of two different ways:
Left-click to activate dynamic rotate mode. Once active, click-
and-drag in the graphics area to rotate the model. Right-click to
deactivate.
Right-click to activate dynamic spin mode. Once active, right-
click in the graphics area and hold the mouse button down to
make the model spin. Left-click to deactivate.

Pan modes Pan modes: this functions in one of two different ways:·
Left-click to activate pan mode. Once active, click-and-drag in the
graphics area to pan the model view. Right-click to deactivate.
Right-click to activate center mode. Once active, right-click in the
graphics area to change the graphics area center. Left-click to
deactivate.

Rotate (left/ Click the left mouse button to rotate the model leftward, and the
right) right button to rotate it rightward.

Rotate (up/ Click the left mouse button to rotate the model upward, and the
down) right button to rotate it downward.

Exercise 1: Opening a database file and using the toolbar

Step 1: Load the HyperForm RADIOSS One Step environment file

1. Start HyperMesh.
2. On the Preferences menu, click User Profiles….
3. For Application, select Manufacturing Solutions. Verify that HyperForm and RADIOSS One Step
are selected.
4. Click OK.

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Step 2: Load the model file
1. From the File menu, select Open.
2. In the Open File dialog, change the Files of type: field to All files.
3. Navigate to the 1Step folder, click on the file Die_Mesh.hm and click Open.

Step 3: Change the visualization of the model

1. In the Model browser, expand the Master Model folder, and then Component folder.
2. Right-click on the Binder component and select Hide. Notice the Binder mesh is no longer displayed
in the graphics area. Right-click on it again and select Show.

3. From the toolbar, click the Shaded Elements & Mesh Lines icon to re-draw the model
geometry in shaded mode.

4. From the toolbar, click the Wireframe Elements icon to re-draw the model geometry in
wireframe mode.

5. From the toolbar, click the Element Color Mode icon and select By Mat from the selection list.
Notice that the Binder and Addendum components become a gray color. This indicates the two
components share the same material.
6. Repeat step 5 and change the setting back to By Comp.
7. From the Preferences menu, click Colors.
8. The graphics area is displayed as a gradient color. You can change both the lighter and darker colors.
Click the color box next to Background 1 and Background 2 and select other color options. This
changes the background color to your selection.
9. Click Reset to restore the default settings.
10.Click Close to close the dialog.

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11.From the toolbar, right-click Pan modes .
12.Move the mouse cursor to graphics area, keep on holding the right mouse button and pan the model
graphically.
Move the mouse cursor back to toolbar menu to release the panning action.
Note: Pan action can also be achieved by holding Ctrl keyboard + right mouse button.

13.From the toolbar, left-click Rotate Mode icon to enter dynamic rotate mode.
14.Click and drag in the graphics area to rotate the model.

15.From the toolbar, left-click Incremental Zoom icon to zoom in on the model.

16.From the toolbar, click Fit View icon to fit the model on the screen.

Main Menu

From the main menu you can access to a variety of panels grouped by the selected user profile.

The main menu with the RADIOSS One Step user profile loaded

Toggles and Switches

Toggles and switches allow you to select and specify options that need to be determined before you
complete the function.

Click a toggle to alternate between two options.

Click a switch to display a list of options in a pop-up

menu.

Reset button. This removes selection and back to empty

value

Utility Menu

The Utility menu is located on the left side of the graphics region and can be relocated by clicking View

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> Tab Area. When Manufacturing Solutions and HyperForm working environments are loaded, the
Utility menu is automatically switched to the HyperForm working environment. It provides tools for
defining/reviewing/editing a model. The Model tab option enables the Model browser functionality.
The user profile selection buttons are at the bottom of the menu.

1Step
Quick access/switch to the RADIOSS One Step
user profile
RADIOSS
Quick access/switch to the
Incremental_RADIOSS user profile
Die
Quick access/switch to the Die Module user
profile
Disp
Tools for visualization purpose
Util
Utilities to perform operations at geometry
level.
User
User-created macros only
Dyna
Quick access/switch to Incremental_LS-DYNA
user profile
To hide the Utility menu:
From the View menu, uncheck the Utility
menu.
To display the Utility Menu:
From the View menu, check the Utility menu.

The Menu Bar

The menu bar, located just beneath the title bar, enable access to many types of functionality. Most
menu options access panels, but some options perform other tasks such as configuring the layout of the
HyperForm environment.

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When the HyperForm environment is loaded, the menu bar also enables you to access to the
fundamental menus regardless of the customization of the HyperForm interface.

Session 2: Using the online help

HyperForm includes a help system to provide information about using the interface. There are several
methods of accessing and using the online help system.

Method 1: Start online help from the pull-down menu

This method provides access to all information.
1. Stay in the main menu; do not click any panel.
2. From the Help menu, select HyperForm. The HyperForm online help is launched.
This book contains all information including Release Notes, User’s Guide, Reference Guide, Tutorials,
etc.

Method 2: Start context-sensitive help

This method allows you to search information specifically for individual panels.
1. Click any panel from the main menu, for example, the Sections panel, and stay in the selected
panel.
2. From the keyboard, press the H key. This directly enters the help function for the selected panel. The
information for the Sections panel is displayed on screen.

Method 3: Finding information using the tabs

You can also search information by typing any keyword(s).
1. Stay in the main menu; do not click any panel.
2. From the Help menu, select HyperForm.
3. Click on the Index or Find tab, and type in the desired keyword(s). A list of related topics is
displayed.

Session 3: File input and output

File input and output is performed through the File menu.

Option Description

File - Open/Save/ Saves and retrieves HyperForm binary database files.

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Save As There are no restrictions placed on HyperForm database
file extension names other than those imposed by the
operating system.
To load a HyperForm database file on top of another
HyperForm database file (*.hf ), use the import option.

File - Import Loads CAD generated geometry or finite element model

information.
It is possible to import a CAD generated geometry or a
finite element model information file into a HyperForm
database file.
HF PARM translator is used to import one step
analysis ASCII input file

File - Export Writes an ASCII file in a format specific to the selected

analysis code.

Load Load a the template file used to format the HyperForm

database for a specific analysis code, or load a Results
file, or a Macro file.

Run Run a command file or a TCL script

Session 4: The Concept of a Collector

Collectors store entities, grouping together all the data pertaining to an entity and allowing you to
handle the data as a group. Collectors in HyperForm consist of the Components, Materials and
Sections (for Incremental_RADIOSS and Incremental_LS-DYNA analysis) panels.
The component and material collectors in HyperForm have specific data associated with them. In one-
step analysis, the component collector contains thickness data while the material collector holds the
Young’s Modulus of Elasticity value and other constants.
All entities in a HyperForm database are stored in collectors. Based on the analysis type, each collector
may use a dictionary or card image to define the attributes assigned to the collector.
The Collectors panel allows you to create and update collectors and assign and edit card images or
dictionaries. Before you build a model, create a component collector for storing or organizing different
data.

Exercise 2: Understanding collectors and using online help

The Die_Mesh.hm file from Exercise 1 should still be loaded in HyperForm.

In steps 1 through 6, you will practice changing the visualization of component collectors.

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1. In the Model browser, click on the Mesh icon next to the Part component to turn off the display of
the mesh for that component. Notice the mesh of the Part component is no longer displayed in the
graphics area. The surface of the Part component is still visible.
2. Click the Mesh icon to turn the mesh display back on.
3. Similarly, click the Geometry icon next to the various components to turn their display on and off.
When finished, right-click on the Components folder and click Show to display all of the
components completely.
In steps 4 though 11, you will review card images, assign a new material to the Part component, and
use the online help.
4. From the Application menu, select Incremental_RADIOSS.
5. From the main menu, click the Components panel.
6. Double-click component: and select Part. The associated material is displayed. Notice material =
Rigid_material.
7. Click edit card to review the card image in solver definition.

8. Click return to go back to the Components panel.

9. Click material: and select CRDQ Steel material.
10.Click update. Notice the associated material is now changed to CRDQ Steel.
11.Press the H key to start the online help. The online help is launched, displaying the help topic for the
panel. Review information for the Components panel. Return to the main menu when finished.

Session 5: Secondary Menu

The secondary menu contains several stand-alone functions, like calculating the distance between two
points. Accessing the secondary menu interrupts the active main panel and allows you to perform a
function from the secondary panel and then return to the main panel. For example, a user can access
the secondary menu by pressing the function keys, F1 through F12, Shift F1 through shift F12, and
more.

Menu Items

The menu items on each panel allow you to specify settings and enter information that is needed to
perform the panel’s function. Panels can contain subpanels, function buttons, toggles, switches, entity
selectors, direction selectors, data entry fields, input fields, and pop-up menus.

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In the following discussion of menu items, you will be using the Translate panel. Access it from the
Geometry menu.

Entity Selector

The entity selector allows you to choose the type of entity to be modified when performing a function.
The entity selector may or may not have a switch ; some panels perform a function on only one type
of entity. The entity selector button is yellow; when it is surrounded by a blue box, the collector is active
and ready for you to select or pick the entities to be processed. You can click on the switch to change
the entity selector type.

Direction Selector

The direction selector allows you to define a plane or vector by using the global x, y, or z axis, or by
selecting a vector, or by selecting nodes in the database.

Direction selector pop-up menu

x-, y-, and z- Specify a direction along any one of the global
axis axes.

vector Use a pre-existing vector entity (something you

can create using the Vector panel) to define a
direction.

N1, N2, N3 Create a user-defined direction. Selecting two

nodes, N1 and N2, allows you to define a vector
direction with base point at N1 toward N2.
Selecting three nodes, N1, N2, and N3, allows you
to define a plane with base point at N1 (unless
otherwise specified). The vector is normal to the
plane and its direction is determined by the right
hand rule.

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 Direction vectors for 2 point and 3 point definitions

Reset Clears the node selections.

Input Fields

Input fields are used to enter text or numerical values. A description of the type of input precedes the
field.

For numeric input fields, you can use the keyboard to enter the value or double-click the input field and
use the pop-up calculator to enter the value.

An example to input values and operations is as below:

"0.0 (default) + 6" will need to be inputted as 0.0(default), 6, +, enter

Pop-up Menus

Pop-up menus display when there are several options from which to choose.
For example, the extended entity selection menu (shown below) allows you to specify alternate methods
for selecting entities of the current data type. To use the extended entity selection menu, click the
yellow data type button of the entity selector. The menu automatically closes when you have made your
selection.
Notice the grayed-out options within the pop-up menu indicates that the function is disabled in the
selected entity selection menu.

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Function Buttons

The color of the menu button corresponds to its purpose:

Green Carries out a function or a command.
Red Exits a panel or aborts a command.

Exercise 3: Translating Elements

The Die_Mesh.hm file from the previous exercise should still be loaded in HyperForm.

Access the Translate panel by hot keys

1. From the Geometry menu, select Translate.

All selections under the Translate option are displayed. SHIFT + F4 is the hot key for the Translate
function.
2. Press SHIFT + F4 to access the Translate panel directly.

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Select the elements to translate
1. Click the entity selector switch . A pop-up menu is displayed, listing all the entity types that can
be modified with the Translate panel. The mouse cursor is located at the center of the pop-up menu.
2. Select elems to specify "elements" as the entity type you want to translate.
After you select elems, the pop-up menu automatically closes. The yellow entity selector button
displays "elems" and the button has a blue border to indicate that it is active.
3. Click elems. The extended entity selection menu displays, with the mouse cursor in the center.
4. Select by collector to indicate you want to select the elements by component collector. After you
select by collector, a list of component collectors is displayed.
5. In the graphics area, pick a cyan element by clicking near its element handle (the dot in the center
of the element). Selecting this element also selects the component collector containing the element,
Part in this case.
The element picked is momentarily highlighted white. The check box preceding Part has a white
check mark in it.
6. Click select to select all the elements in the component collector, Part, as the elements to be
modified when you use the translate function.
The Translate panel again displays and all of the elements in the Part component are highlighted.

Specify a direction to translate the selected elements

1. Click the direction selector switch. A menu is displayed with a list of plane and vector options for
translating the selected entities. The mouse cursor is located at the center of the pop-up menu.
2. Click N1 N2 N3 to select the N1, N2, N3 method. The pop-up menu automatically closes.
3. Click N1.
The blue border around N1 indicates it is active. The selected elements in the graphics area are now
gray because the entity selector is not active.
4. In the graphics area, pick a node. A green circle displays in the graphics area at the node that was
picked. The N1 button no longer has a blue border, but the N2 button does. N2 is currently active.
5. In the graphics area, pick any other node. A blue circle displays in the graphics area at the node you
specified. The N2 button no longer has a blue border, but the N3 button does. N3 is currently active,
but in this case, a node for N3 will not be specified.
6. In the graphics area, right-click the blue circle to deselect the node N2. The blue node N2 is not
displayed in the graphics area. The N2 button now has a blue border.
7. In the graphics area, pick a different node. This new node is the new N2 node. A blue circle displays
in the graphics area at the node you specified.

Specify a distance to translate the selected elements

1. Double-click magnitude =. The calculator pop-up menu appears.
2. Input 50.0, click ENTER and click exit to leave the calculator.
3. Click translate +. The highlighted elements move 50 units in the positive N1-N2 vector direction
with N1 being the vector’s base node and the vector passing through N2.

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4. Click reject to reject the translation action.
5. Click f on the keyboard. The model is resized to fit the screen.

Session 6: Default HyperForm Files

HyperForm includes or automatically creates several default files. These include:

hm.cfg configuration file

hmmenu.set user interface settings
command.cmf command file

hm.cfg
The hm.cfg file is a default configuration file read on start-up. The hm.cfg file controls many aspects of
how HyperForm runs at your particular site. You can edit the commands in the hm.cfg file to your own
preferences.
command.cmf
The command.cmf file is a standard ASCII file that HyperForm reads and writes. Command files allow
you to retrieve a work session in case of a system crash or program a series of procedures. You can use
a command file in applications that contain repetitive steps or you can create demonstrations.
All commands executed by the HyperForm command processor are written to this file. This file is
automatically created in the directory in which you started HyperForm. If the file already exists, new
commands are appended to the existing file.
For more information about the command.cmf file, please see the HyperForm online help topic HyperForm
Commands.
hmmenu.set
The hmmenu.set file is a binary file that HyperForm updates when you exit HyperForm. Your personal
hmmenu.set file stores many global parameters and is located in the directory from which you started
HyperForm. If the file already exists, it is overwritten after you run a new session. The most recent
global parameter values in the current HyperForm session are written to this file when you exit. The next
time you start HyperForm, it has the values recorded in the hmmenu.set file. If the file does not exist
when HyperForm is invoked, the global parameter values are default values.

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RADIOSS One Step Tutorials
HF-0150: Quick Setup
HF-0200: Geometry Cleanup
HF-0300: Automeshing
HF-0400: Mesh Quality
HF-0500: Model Preparation - Undercut Check and Autotipping
HF-1000: One Step Stamping Simulation
HF-1010: Increasing Blankholder Pressures
HF-1020: Applying Drawbeads to a Model
HF-1030: Transferring Forming Results to Crash Analysis
HF-1040: Laser Weld
HF-1050: Trim Line Layout

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HF-0150: Quick Setup

This tutorial describes the steps required for modeling and running one step analysis that can be
performed in HyperForm within the RADIOSS One Step user profile.
The following steps are involved in one step analysis:
1. Geometry cleanup and meshing
2. Assigning materials and thickness
3. Defining symmetry
4. Defining blankholders
5. Defining drawbeads
6. Setting the stamping direction either by tipping the part or by using the existing part orientation as
the forming axis
7. Checking for undercuts
8. Running the analysis

Exercise 1: Geometry Cleanup and Meshing

This exercise uses the model file Part1a.igs. The following image shows the program with the
RADIOSS One Step user profile and model file loaded:

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Step 1: Load the model file
1. Click File > Import > Geometry icon.

2. Click the Select Files icon and browse to the file <installation_directory>\tutorials\mfs
\hf\1Step\part1a.igs.
3. Click Import and then click Close.

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Step 2: Geometry cleanup
1. In the OneStep tab, right-click on Parts > New > Pick as shown in the image below:

Note: The component name is recognized automatically as Part once the model is loaded into the
session.
2. Pick the part from the screen.
3. Click proceed. The material CRDQ steel and a thickness of 1 mm is assigned to the part by
default.
4. Right-click on the part lvl1 and select Geometry > Remove Holes.

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 5. In the diameter< field, enter 40.
6. Click on the yellow surfs button to highlight it. Click again and select displayed from the
extended entity selection menu. This selects all the entities on the screen.
7. Click find. All pinholes found are highlighted with xP.
8. Click delete to close the hole.
9. Click return to close the panel.

Step 3: Meshing the part

1. Right-click on the part lvl1 and select Mesh > R-Mesh.
2. Enter the values, as shown below:

3. Click Mesh.
4. Click Close.

Exercise 2: Setting up One Step Analysis

Step 1: Assigning the material and thickness to the part

1. Right-click on CRDQ Steel and select Database to change the material selection.
Note: A user-defined material can also be added to the database by editing the material file
hf.dat.

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2. When finished viewing/changing the material selection, click Close to close the dialog.
3. Highlight Thickness:1 by clicking on it once. Double-click on the digit 1 to make it editable and
change the value to 1.5.

Step 2: Setting symmetry conditions

1. In the OneStep tab, right-click on Symmetry:No and select Edit.

Step 3: Setting the stamping direction

1. Right-click on Stamping Direction:X and select Z.

Note: Stamping can also be done in any of the three principal

axes or an arbitrary axis in space by using Stamping
Direction in the Autotip panel. Use the stamping direction
subpanel to specify the stamping in an arbitrary direction.

In the Autotip panel, use the vector selector switch to assign a direction. If the stamping
direction of the part is not one of the principal axes, use the N1, N2, N3 option and select 2
nodes on the model to define a direction.
Click set.

Step 4: Selecting the blankholder

Blankholders can be defined as the upper and lower holding surfaces that control metal flow around a
shape to be formed in a draw operation. They supply a restraining force on the material during the
pressing process.
HyperForm allows you to define the blankholder force in two ways: on element and on edge. The
correlation between the magnitude and level of the applied forces is always available. Edge
blankholder force application allows you to restrain an edge by enabling automatic selection of all
nodes between two user-defined nodes along a free edge of a part.
You can define the blankholder force in two ways: tonnage force or pressure level (high, medium and
low).

Note: The pressure level is proportional to the area of blank under

the blankholder as well as thickness. A pressure level of 2MPa,
5MPa and 10MPa for a 1mm blank has been chosen as a
reference for Low, Medium, and High (based on practical
experience). The tonnage (metric ton unit) is equivalent to the
pressure times the blankholder area normalized/scaled by the
thickness (1 metric ton = 9810N).

1. In the OneStep tab, right-click on Blankholders > New. If desired, you can double-click on
Blankholder1 to change the name.
2. Right-click on Blankholder1 > Elements…

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3. Click elems and select on plane.
4. Select z-axis and pick a node on the binder (flat region) for B (base node).
5. Click proceed. Friction, Tonnage and Pressure level appears below Blankholder1.
6. Double-click on the values for Friction and Tonnage to change the values.
7. Right-click on Pressure Level: and select Medium.
Notice that the Tonnage changes according to the selected pressure level.

Step 5: Creating drawbeads

Modeling the exact drawbead geometry requires a large number of elements, which increases CPU
time dramatically. A practical approach is to use an equivalent drawbead model by representing the
drawbead analytically and providing a constant drawbead restraining force and closure force.
Use the calculate subpanel to determine the closure and restraining force based on drawbead
dimensions. The restraining force is the value of the force (per unit length) applied by the bead in
the plane of the blank surface. The closure force is the force (per unit length) required in the
perpendicular direction to keep the drawbead closed.

1. From the OneStep tab, right-click on Drawbeads > New > Restrain….
2. Pick two nodes on the part as indicated in the image below to define the drawbeads.

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3. Click Proceed. A message shows "The drawbead set has been created." A line representing
drawbeads is created.
4. Notice that Drawbead1 is created with a default Restraint Force and Pressure Level. Double-click
Drawbead1 to rename it.
5. Right-click on Pressure Level > Medium. Notice that Restraint Force changes based on the
Pressure Level selection.

Step 6: Tipping
1. Right-click on the OneStep tab anywhere in the red box as shown below and select Autotip.

2. Select the autotip radio button.

3. Verify the entity selector is set to comps and select the lvl1 component.
4. Verify the toggle is set to full model and keep the rest of the options as default.
5. Click calc autotip.
Notice the angle to be tilted is displayed on the header bar on the left hand bottom corner and
the magnitude is displayed in the angle field.
6. Click autotip. This action will tilt the part by an angle calculated by HyperForm to reduce draw
depth during forming.
7. Click return.

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 Step 7: Checking for undercuts
1. Right-click on the OneStep tab anywhere in the red box as shown above and select Undercut
Check.
2. Click on the yellow comps button to highlight it.
3. Pick the part from the screen.
4. Click on check undercut.
Notice the message “0 elements with undercut detected”. If there are undercuts in the model
then the failed elements are highlighted on the screen.
5. Click return.

Step 8: Checking the model and running the analysis

1. Right-click on the OneStep tab anywhere in the red box as shown above and select Check
Model. A message is displayed on the message bar, stating “Model checked.”
2. Right-click on the OneStep tab and select Run.
3. Enter a name for the run. The feasibility solver launches.
Note: It is advised to run the analysis into a separate folder.

Exercise 3: Post processing

After the successful completion of the run, right-click on the white space of the OneStep tab to see
the Blank Shape, %thinning and Formability options, which were not available before running the
analysis.

Right-click and select the desired result type for post-processing.

Step 1: Blank Shape

1. Right-click on the OneStep tab anywhere in the white space and select Blank Shape.
2. Under Blank Shape Profile: click Initial. Notice that the initial blank shape is displayed on the
screen, as shown below.

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3. Click export to write out an iges boundary of the predicted blank shape to the folder where
feasibility analysis was run. The file will be named as <filename>_blank.iges.

Exercise 4: Blank Fit

Step 1: Fitting the initial blank shape into different configurations

1. From the Tools menu, click Blank Fit. This will bring up the blank fit utility, as shown below:

2. Use the Part drop down menu to select the component on which the one step analysis was run.
3. Keep the default values for Density and Cost per Kg.
4. Under PLOT OPTIONS, click the checkbox next to %Thinning and Formability. Notice that %
Thinning and Formability buttons becomes active.
5. Rotate the model to a desired direction and click %Thinning. This contours the model with %
Thinning result type.
6. Left-click to capture the image to include it in the report. A right-click will abort the function and
return to the Blank Fit macro. This is indicated by the image on the right hand bottom corner of
the graphics area .

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7. Under BLANK SHAPES, check all the boxes.
8. Click Blank Fit. This will fit the blank into the selected shapes.
9. Click Publish Report. This will open a HTML report with hyperlinks to blank shapes and results, as
shown below.

11.Click Close.

Exercise 5: Blank Nest

Step 1: Nesting the initial blank shape on coil or sheet

1. Click Tools > Blank Nesting.
2. Click elems >> displayed.
3. Click nesting. A new window called Blank Nesting opens which allows you to nest the blank in
different configurations.

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4. Right-click any where on the blank shape and select Duplicate. This will create a duplicate of the
existing blank shape.
5. Right-click anywhere on the blue screen and select Auto nesting from the menu. This will make
the best fit of the 2 shapes of the blank on a sheet.
6. Click File > Export.
7. Enter a name and click Save. This saves an .iges boundary of the nested sheet.
8. Select File > Exit to close Blank Nesting.
Note: There is a detailed explanation of all the options in Blank Nesting in the HyperForm online
help.

Exercise 6: Report Generation

Step 1: Publishing a report of the feasibility analysis results

1. Click Tools > Report Generator. The Report Generator opens up, as shown below:

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2. Click the Result File: file browser icon and select <filename>.res in the folder where you have
run the feasibility analysis.
Note: You must run feasibility analysis in a separate folder with no spaces in the path and in the
folder name.
3. Click the Report Name: file browser icon and type a name for the report. The folder and report
name must not have any spaces in the folder name or file name.
4. Check all the boxes under Result Types.
5. Under Export Mode, select HTML.
6. Under Export Options, select JPEG.
7. Click Generate. This creates a report in the folder selected in the Report Name field. It includes
folders called <filename>_data_dir and <filename>.hml.
8. Open the folder that was selected for Report Name. Open the file <filename>.html in Internet
Explorer or Firefox. This opens a html page with hyperlinks to the selected result types and the
corresponding image with contour, as shown below:

9. Click Close to close the panel.

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HF-0200: Geometry Cleanup

When designers create CAD geometry, their priorities are different from those of analysts trying to use
the data. A single smooth surface is typically split into smaller patches, each a separate mathematical
face. The juncture between two surfaces often contains gaps, overlaps, or other misalignments.
To make the geometry more appropriate for meshing, analysts need to combine a number of faces into a
single smooth surface. A single, smooth surface not only allows the elements to be created on the entire
region at once, but also prevents unnecessary artificial or accidental edges from being present in the
final mesh.
Sometimes, the gaps, overlaps, and misalignments present when surface data is imported can affect the
mesh quality. By eliminating misalignments and holes, and suppressing boundaries between adjacent
surfaces and unnecessary details, you can automesh across larger, more logical regions of the model
and improve the overall meshing speed and quality.
In this tutorial, you will use a variety of tools to prepare surface geometry for meshing.

Tools

Auto Cleanup panel

The Auto Cleanup panel performs automatic geometry cleanup.

Quick Edit panel (F11 hotkey)

This panel combines many tools for rapid editing of model geometry.

Exercise 1: Reviewing geometric problems

In this exercise, you will first review a variety of common geometric problems after reading a CAD file.
The solutions are discussed in Exercise 2.

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This exercise uses the model file Bpillar_cleanup.hf.

Step 1: Load the model file

1. Click File > Open....
2. Browse to the location <Installation Folder>\tutorials\mfs\hf\1Step and select the
Bpillar_cleanup.hf file.
3. Click Open.

Step 2: Review the model in Topology color mode

1. Click View > Toolbars > Visualization to display the Visualization toolbar. The Visualization
toolbar will need the panels displayed also in the View menu.

2. From the toolbar, select Geometry Color Mode and change to By Topo. Notice the color of
the model is changed and topology definitions are displayed on screen.

3. From the toolbar, click Shaded Geometry & Surface Edges icon to shade the surfaces on
screen.
The model comes in with several geometric problems after importing. You will first review the
problems to have a better understanding of the nature of the model.
In Topology color mode, each color represents different topological modes:

Free (Red color): The edge is owned by one surface. On a clean model,
edge free edges appear only along the outer perimeter of the part and
internal holes. Free edges that appear between two adjacent
surfaces indicate the existence of a gap between the two surfaces.

Shared (Green color): The edge is owned by two adjacent surfaces. When
edge the edges between two adjacent surfaces are shared (green), there
is no gap or overlap between the two surfaces, and they are
geometrically continuous. The automesh utility always places seed
nodes along their length and will produce a continuous mesh
without any gaps along that edge. The automesh utility will not

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 construct any individual elements that cross over a shared edge.

Suppres (Blue color): The edge is owned and shared by two adjacent
sed surfaces but it is ignored by the automesh utility. They are blue
edge dotted lines by default. Like a shared edge, a suppressed edge
indicates geometric continuity between two surfaces but, unlike a
shared edge, the automesh utility will mesh across a suppressed
edge as if were not even there. The automesh utility does not place
seed nodes along their length and, consequently, individual
elements will span across it. By suppressing undesirable edges you
are effectively combining surfaces into larger logical meshable
regions.

Non- (Yellow color): The edge is owned by three or more surfaces. They
manifol typically occur at "T" intersections between surfaces or when 2 or
d edge more duplicate surfaces exist. The automesh utility always places
seed nodes along their length and will produce a continuous mesh
without any gaps along that edge. The automesh utility will not
construct any individual elements that cross over a nonmanifold
edge. These edges cannot be suppressed and can sometimes be
indication for duplicated geometry.

Step 3: Review and measure the largest pinhole diameter

1. From the toolbar, select the Visualization icon .

2. From the Visualization tab, select the Topology icon and clear the Shared, Suppressed and
Non-manifold check boxes. Only the red free edges display.
3. Click Close to close the Visualization tab.
4. Press T on your keyboard and input thetax = -101.154, thetay = -59.845 and thetaz =
109.363.
5. Click set angles to set the true view.
6. Notice several pinholes, as shown in image below.

Notice the biggest pinhole as indicated in the left side of the image is considered as a part of the
feature and will be kept. The smaller holes on the flange area are considered removable.
7. Press F4 on the keyboard to go to the Distance panel.

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8. Hold the Ctrl key and middle mouse button to draw a circle to zoom in the center bigger pinhole
on the flange, as indicated in the image below.

9. In the Distance panel, select the two nodes option. Notice a halo is surrounding N1.
10.Hold the left mouse button and move the mouse cursor to the N1 location on top of the hole
(location A in the image) until the hole is highlighted. Release the left mouse button and click
again to create a temp green node created on top of the hole.
11.Repeat the same procedure for N2 to create a second blue temp node as shown as location B in
the image.
12.Notice the diameter of the hole (value next to distance = ) is about 3.2.
The approximate diameter of the largest hole is about 3.2. Remember this value so you can apply
it when you remove pinholes later.
13.Press F on the keyboard to fit the model to the screen.
14.Click return to close the panel.

Step 4: Review free edges

1. From the toolbar, select the Wireframe Geometry icon .
2. Notice several red lines as shown as in the image below. An example can be found as indicated
where an arrow is pointing.

Free edges that appear between two adjacent surfaces indicate the existence of a gap between the two surfaces.

Step 5: Review a missing surface

1. From the toolbar, select Shaded geometry and surface edges . The surfaces are shaded on

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 the screen.

2. From the toolbar, select the Visualization icon .

3. From the Visualization tab, select the Topology icon and check Shared, Suppressed and
Non-manifold to turn on the display of all definitions.
4. Click v on the keyboard to open the dialog with saved views.
5. Click restore 1 to display the previously saved missing surf view.
6. Notice the missing surface as shown in the image below.

Step 6: Review the distorted surface

1. Click v on the keyboard to open the dialog with saved views.
2. Click restore 2 to display the previously saved distorted surf view.
Notice the dark shadow on top of the surface as indicated in the image below.

You will use the Automesh panel to verify the quality of the surface in the following procedures.
3. Click Mesh > Auto Mesh.
4. Click surfs and select only the surface with dark shadow. Notice two surfaces are selected as
shown in the image below. This is a first indication of distorted surface.

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5. Click element size = and input 0.5.
6. Click mesh. The mesh pattern has poor quality and higher node density at the center area (along
the center shared edge). This is a second indication of the distorted surface.

7. Click abort to abort the meshing operation.

8. Click return to close the panel.

Step 7: Review the duplicated surface

In this model, you have duplicated surfaces existing in this model.
1. Click v on the keyboard to open the dialog with saved views.
2. Click front to review the front view. Notice the yellow lines surrounding the surface as indicated by
an arrow below:

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3. Click Geometry > Defeature and then select the duplicates subpanel.
4. Click the switch and change to faces.
5. Click find. The two surfaces are highlighted and identified.

Step 8: Review deviated trim line

1. Click v on the keyboard to open the dialog with saved views.
2. Click restore 3 to display the previously saved improve share view.
Notice the deviation of one trim line as circled in the image below. The deviation of the trim lines
could cause poor mesh quality. An ideal trim line will look like the dash line on the right hand side
of the image below. You will correct this problem later.

Step 9: Review incorrect fixed point definition

1. Click v on the keyboard to open the dialog with saved views.
2. Click restore 4 to display the previously saved fixed point view.
Notice the incorrect definition for the free boundary. This is due to the incorrect definition of the
fixed point, as indicated in the image below.

Exercise 2: Fixing geometric problems

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In this exercise, you will use a variety of tools to fix the geometric problems.

Step 10: Remove pinholes using the Auto Cleanup panel

1. From the Geometry menu, select Autocleanup.
2. Click edit parameters to launch the Parameters File editor to modify Auto Cleanup settings.
3. In the Parameters File editor, clear all settings under Other options.
4. Click the next to Other options and change to . This disables the other options.
5. Repeat the steps above and disable all options EXCEPT Geometry cleanup and Surface hole
recognition.

6. Click (Delete line) to delete the second row under Surface hole recognition.
7. In the first row under Surface hole recognition, input 4.0 under R< and check Remove. The
final result should look like the image below. Since the largest diameter of the holes on the flange
is about 3.2, using the value 4.0 can make sure all the holes on the flange will be removed.
8. Change Target element size: to 3.0. The target element size is the desired mesh size after
geometry cleanup.

9. Click Apply and Ok to return to the Auto Cleanup panel.

10.Click surfs >> all from the pop-up window.
11.Click autocleanup.
Notice the cleanup process is launched. A message is displayed "There is a conflict between the
user requested element size of 3 and the quality criteria ideal element size 0.5 used in the
optimization, How do you wish to proceed?"
12.Click Continue.
When the cleanup process is finished, a message "Geometry cleanup process is finished" is

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 displayed in the status bar. After the auto cleanup process, notice that:
The four holes on the flange are removed.
The number of free edges (red edges) is reduced as shown in the image below. If you wish to
see only the free edge definitions, select the Visualization icon and deactivate all topologic
definitions EXCEPT Free edges.
Duplicate surfaces are removed.

13.Click return to close the Auto Cleanup panel.

Step 11: Fix the missing surface using the Quick Edit panel
In this step, you will manually clean up geometry using the Quick Edit panel.

1. From the toolbar, select the Visualization icon and activate all topologic definitions.

2. From the toolbar, click the Shaded Geometry & Surface edges icon to shade surfaces.
3. Click v on the keyboard to open the dialog with saved views.
4. Click restore 1 to withdraw previously saved missing surf view.
5. Click F11 to access the Quick Edit panel.
6. Click the line(s) button right next to filler surf:. A blue halo appears and surrounds the line
button.
7. Click any red edge of the missing rectangular surface. A surface is created to fill the missing
surface. Notice the previous four free edges are now changed to a green shared edge.
8. Click return to close the panel.

Step 12: (optional) Delete the distorted surface and recreate it

Using the Auto Cleanup function, most of the time, distorted surfaces are removed automatically. If
you do not see distorted surfaces after the Auto Cleanup operation, skip this step.
1. Click v on the keyboard to open the dialog with saved views.
2. Click restore 2 to display the previously saved distorted surf view.

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3. Press F2 on the keyboard to go to the Delete panel.
4. Click the entity selector and change it to surfs.
5. Click surfs and select the distorted surface (the surface with dark shadow) from the screen.
6. Click delete entity. This action deletes the distorted surface.
7. From the menu bar, click Geometry > Create > Surfaces > Ruled.
8. If necessary, click the switch to set the selection to line list. Click the upper line list selector and
select the three red edges, as shown in the image below.
9. Click the lower line list selector and select the one red edge, as shown in the image below.
10.Verify that Auto reverse is activated.
11.Click create.
12.Click return.

Notice a new surface is created at the same location. The new surface has three shared (green)
edges and one free (red) edge as indicated in the image below.

13.Press the F11 key to open the Quick Edit panel.

14.Click the line(s) button right next to toggle edge:.
15.Change the tolerance to 0.1. This is the geometric cleanup tolerance.
16.Use the left mouse button to click the red free edge to turn it into a shared green edge.

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17.Click return to close the panel.

Step 13: (optional) Delete the duplicated surfaces

Using the Auto Cleanup function, most of the time, duplicated surfaces are removed automatically.
This step is optional if you wish to remove duplicated surfaces manually without Auto Cleanup. If you
don’t see duplicated surfaces after the Auto Cleanup operation, skip this step.
1. Click Geometry > Defeature.
2. Select the duplicates subpanel.
3. Change the entity selector from surfs to faces.
4. Click faces and select all from the pop-up window.
5. Click find. Notice two duplicated surfaces are highlighted and identified.
6. Click delete to remove the duplicated surfaces.

7. From the toolbar, select the Visualization icon .

8. From the Visualization tab, select the Topology icon and uncheck Shared, Suppressed and Non-
manifold to turn off the display of all definitions EXCEPT free edge (red line).

9. From the toolbar, select the Wireframe Geometry icon .

Notice a red circular line indicating free edge. Since there is no hole existing, it indicates a
problem with redundant surface.

10.From the toolbar, click the Shaded Geometry & Surface edges icon to shade surfaces.
11.Press F2 on the keyboard to go to the Delete panel.
12.Change the entity selector to surfs.
13.Hold the left mouse button and move the cursor to the red circular line until the circular surface
edge is highlighted. Let go of the left mouse button and click delete entity to delete the surface.
Refer to the image below.

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14.Click return to close the panel.

15.From the toolbar, select the Visualization icon .

16.Check Shared, Suppressed and Non-manifold to turn on the display of all definitions.

Step 14: (optional) Relocate a shared edge

Using the Auto Cleanup function should have relocated this edge. If you do not see this edge after
the Auto Cleanup operation, skip this step.
1. Click v on the keyboard to open the dialog with saved views.
2. Click restore 3 to display the previously saved improve share view.
3. Click F11 to access the Quick Edit panel.
4. Click the Points panel right next to replace points:. The function is activated.
5. Click points and click the fixed point B as shown in the image below
6. Click retain and click the fixed point A as shown in the image below.
Notice the two fixed points are now merged. Point B is moved to point A.

7. Repeat steps 5 and 6 to merge point C and point D by moving point D to the location of point C.

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Step 15: Fix the incorrect fixed point
1. Click v on the keyboard to open the dialog with saved views.
2. Click restore 4 to display the previously saved fixed point view.
3. Click point(s) for release point to activate this feature.
4. Click the fixed point, as indicated in the image below.

Notice the fixed point is released and some free edges are generated.
5. Click return to close the panel.

Step 16: Merge the two free edges

In the following steps, you will switch two free edges by replacing one free edge with the other free
edge.
1. Click Geometry > Edit > Surface Edges > Replace.
2. Click line under moved edge: and select the line shown as B in the image.
3. Click line under retained edge: and select the line shown as A in the image.
4. Click cleanup tol = and input 1.0.

5. Click replace. Notice the gap is closed and a new share edge is generated.

Step 17: Toggle the remaining red edges into shared edges and un-suppress

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two blue edges
You are still in the Edit Surface Edges panel.
1. Click toggle subpanel.
2. With a blue halo surrounding the edge button, click the two free edges as indicated in the image
below.
3. Notice the two red free edges are now converted into shared edges.

4. Press the t key and input thetax = 145.968, thetay = -79.495 and thetaz = 30.150.
5. Click set angles to set the true view.
Notice three blue suppressed edges are indicated in the image below. You will toggle the blue
suppressed edges and turn these two suppressed edges to green shared edges.

6. Click return to go back to the Edit Surface Edges panel.

7. With the edge button activated, right-click the two suppressed edges to change them to green
shared edges.

Step 18: Save the cleanup result

1. From the File menu, click Save As.
2. Use the file browser to save the file as Bpillar_cleanup_complete.hf.
3. Click save.

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HF-0300: Automeshing

In this tutorial, you are introduced to the meshing capabilities provided in HyperForm.
Several meshing tools are available:
BatchMesher
AutoMesh
R-Mesh (available in RADIOSS One Step, Incremental_LS-DYNA and Incremental_RADIOSS user
profiles)
B-Mesh (only available in the Incremental_RADIOSS and Incremental_LS-DYNA user profiles)
The BatchMesher is an external tool that can perform geometry feature recognition, cleanup and
automatic meshing (in batch mode) for given CAD files without user interaction. Detail of the
BatchMesher will not be discussed in this tutorial. Refer to the HyperWorks online help for more
information about BatchMesher. In this tutorial, you will be introduced to the three meshing modules:
AutoMesh, R-Mesh and B-Mesh.
In HyperForm, most of the element creation panels use the AutoMesh module, which supplies as much
automated assistance as possible. AutoMesh allow you to adjust mesh interactively with a wide variety
of parameters and choose from a suite of algorithms. You can interactively control the number of
elements on each edge or side and you can immediately determine the nodes that are used to create
the mesh. You can adjust the node biasing on each edge to force more elements to be created near one
end than near the other, which allows you to see immediately the locations of the new nodes. The new
elements can be specified as quads, trias, or mixed and can be first or second order elements. The
created mesh can be previewed, which allows you to evaluate it for element quality before choosing to
store it in the HyperMesh database. While you are in the meshing module, you can use any of viewing
tools on the visual options menu to simplify the visualization of complex structures in your model. You
can also re-mesh existing meshing interactively or automatically on surfaces or groups of elements. You
will learn to use a variety of AutoMesh features later in this tutorial.
R-Mesh (Rigid tool surface mesh) allows you to quickly mesh a rigid tool surface by specifying the max
length of element, minimum length of element, chordal deviation, and fillet angle.
B-Mesh (Blank surface mesh) allows you to quickly mesh a blank component. You can specify an
average edge length and mesh selected surfaces. B-mesh is discussed in incremental analysis tutorials.

Exercise: Automeshing with different meshing options

This exercise uses the model files Bpillar_AutoMesh.hf, Bpillar_AutoMesh_remesh.hf and

Bpillar_AutoMesh_remesh_final.hf.

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Tools

The tools in this tutorial can be found in the RADIOSS One Step user profile.
Midsurface
The Midsurface panel allows you to extract the midsurface representation of a solid part.

AutoMesh
The AutoMesh panel allows you to create meshes or re-mesh existing meshing.

R-mesh macro
Rapidly generates a quad/tria shell mesh ideal for representing rigid tool surfaces.

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Step 1: Load the model file

1. From the File menu, select Open....

2. Browse to the file <installation_directory>\tutorials\mfs\hf\1Step\Bpillar_AutoMesh.hf.
3. Click Open.

Step 2: Retrieve the mid-surface

1. From the visualization toolbar, select the Geometry Color Mode icon and change to By Topo.
Notice the color of the model is changed and topology definitions are displayed on screen.

2. From the toolbar, click Shaded Geometry & Surface Edges to shade the surfaces on screen.
The model is a pre-cleanup geometric model with thickness. In reality, it is common to have CAD
data with thickness. You will learn how to extract midsurface in the next steps.
3. From the menu bar, click Geometry > Midsurface.
4. Verify that the auto midsurface subpanel is selected. The default toggle is set to closed solid.
5. Click extraction options.
6. Input max thickness ratio = 2.0 and toggle extract by component to cross components.
7. Click return to exit the Extraction Options panel and return to the Midsurface panel.
8. With surfs activated, graphically pick a surface on screen. All surfaces are selected and
highlighted.
9. Click extract.
Midsurface extraction takes about one to four minutes depending on system performance. Notice
that once the operation is finished, a new component named Middle Surface is created that
contains the extracted midsurface. By default, HyperForm applies the transparent view to the
generated midsurface.
10.Click return to exit the panel.

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Step 3: Prepare AutoMesh

1. Using the Model browser, expand the Components folder and hide all geometry EXCEPT Middle
Surface.

2. Right-click on automesh. In the menu that appears, select Make Current. This sets the
automesh component as default working component.
3. From the File menu, select Save As and enter the file name as automesh_ready.hf.
4. Click Save.

Step 4: AutoMesh – size, biasing and automeshing secondary panel

In this step, you will learn how to interactively mesh a blank using size and biasing control. The size
and bias subpanel allows you to mesh surfaces or re-mesh existing meshes with some control over
how the mesh is created. You can also adjust a mesh on-the-fly during the creation process using this
subpanel.
1. Click Mesh > Auto Mesh.
2. Verify that the size and bias subpanel is selected.
3. Click surfs >> displayed.
4. Verify the following settings:
element size = 3.0
mesh type = mixed
elems to current comp toggle is set (generated elements will be stored in the current working
component automesh component)
first order toggle is set
next to map: the size and skew checkboxes should be selected
Toggle is set to interactive

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5. Click mesh.
Notice a mesh is displayed in the graphics area. You have entered the Automeshing Secondary
panel (inactive mesh module), which allows you to manually adjust mesh before it is finalized.

6. With the density subpanel selected and the adjust: edge option activated, move the mouse
cursor onto any edge density number in the graphics area, and left-click to increase edge density.
7. After the edge density number is modified, click mesh again to preview the modified mesh.
Refer to the following images:

Notes:

adjust: edge allows you to interactively increase/decrease mesh edge density by right-/left-click.
calculate: edge allows you to interactively modify individual edge or all edges based on desired
element size.
set: allows you to interactively modify individual edges or all edges based on a specified value.
8. Select the mesh style subpanel.
Mesh style allows you to specify the meshing and smoothing algorithm to use for each face of each
domain when you are following a surface-based approach to the Automeshing Secondary panel.
9. Under elem type: click the selector and select the trias element type.
10.Click the set all button and press the P key to refresh the screen.
Notice all the element type symbols are changed to tria. Refer to the image below.

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11.Click mesh.
Notice the mesh type and symbol is changed to trias.

12.Click reject to reject the mesh.

13.For meshing algorithm, autodecide is the default algorithm. Review the image below for all the
mapping definitions.

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14.Under elem type: click the selector and select mixed element type.
15.Click set all above the mixed button.
16.Click mesh again.
17.Select the biasing subpanel.
Biasing allows you to control the element density biasing along edges. Element biasing is the
placing of elements along an edge so that element size is smaller at one end than at the other,
and is one way to improve element quality when doing transitioning.
By default, all mesh edge biasing is linear with value 0.0. You can change the biasing style and
increase/decrease biasing factor by left-/right-clicking on the edge biasing numbers.
The following image shows different biasing styles.

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18.Select the checks subpanel. The checks option enables you to check the quality of generated
elements before they are generated.
19.Click jacobian. The default Jacobian value is 0.7. Elements with a Jacobian value < 0.7 are
displayed in red in the graphics area. This option enables you to quickly identify initial quality
before accepting the mesh.
20.Click return twice to close the panels.
21.From the File menu, select Save As and enter the file name as automesh_size.hf.
22.Click Save.

Step 5: AutoMesh – QI optimized

In QI optimized meshing, the surfaces are meshed to optimize the quality index (QI) of the elements
generated. You can either provide a criteria file or update the Quality Index panel with the desired
quality criteria. The surfaces are then meshed with algorithms that produce the best quality index.
The placement of the nodes on the surface is also optimized to improve the QI.
1. Click File > Open.
2. Browse to select the previously saved automesh_ready.hf file and click Open.
3. Click Mesh > AutoMesh.
4. Select the QI optimize subpanel.
5. Input element size = 3.0.
6. Click edit criteria.
7. Set up all the criteria as shown in the following image:

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 Note: It is recommended that you follow these guidelines for
better accuracy:

Warpage should be less than 25

Chordal Deviation should be small. 0.9 is a good threshold
value to start with.
Larger Jacobian values are better. Eliminate negative Jacobian
values to prevent solver crashes. 0.4 is a good threshold
value.
Chordal Deviation should be selected, with a small value (0.9)

8. Click Apply and OK to close the Criteria File Editor.

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9. You are still in the QI optimize subpanel. Uncheck smooth across common edges with. This
step disables the smoothing operation of mesh across minor changes in surface angles.
10.Click surfs >> displayed.
11.While all displayed surfaces are highlighted and selected, click mesh.
12.Click return to accept the mesh.
13.Click File > Save As and enter the file name as automesh_QI.hf.
14.Click Save.

Step 6: AutoMesh – edge deviation

The edge deviation subpanel allows you to set specific meshing parameters to limit how far the mesh
elements can deviate from the actual edges of the surfaces meshed.
The edge deviation normally occurs on curved edges, because individual elements have straight edges
and therefore can only approximate a curve. This automesh sub function automatically chooses the
best element size to approximate a curve, within limits that you specify. Note that this differs from
the size and bias subpanel, which only meshes with elements of a uniform size that you specify.
1. Click File > Open.
2. Select the previously saved automesh_ready.hf file and click Open.
3. Click Mesh > AutoMesh.
4. Select the edge deviation subpanel and set the following options:
min elem size = 0.5
max elem size = 15.0
max deviation = 0.1 (Defines the maximum allowable distance between an edge of the surface
being meshed and an element edge)
max angle = 15.0 (Defines the maximum allowable angle between two element edges).
mesh type = mixed
first order toggle is set
5. Click surfs >> displayed.
6. Click mesh.
7. Click return twice to accept the mesh.
8. Graphically review the mesh. Notice large element size occurs at planar surfaces and smaller
element size is applied to capture curved surfaces.
9. Click File > Save As and enter the file name as automesh_edge_deviation.hf.
10.Click Save.

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Step 7: AutoMesh – surface deviation

Similarly to the edge deviation subpanel, meshing behavior on this subpanel is driven by distances
between flat elements and model geometry. When HyperMesh uses flat elements to approximate a
curved surface, there is always a discrepancy between each element and the actual curve of the
surface, because the element uses a straight line between two nodes.
The surface deviation automesh method chooses the mesh density based on the severity of this
deviation. Where the threshold deviation would be exceeded, HyperMesh uses a larger number of
smaller elements to reduce the deviation.
For more information, please refer to the online help.

Step 8: AutoMesh – rigid body mesh (R-mesh)

Rigid bodies are surfaces that are expected to impact other model surfaces, but are rigid enough that
they themselves are not expected to deform as a result of the impact. When modeling the results of a
stamp pressing down on a metal sheet, it’s important to model the shape of the stamp because that
determines the shape of the metal sheet after being pressed. However, it is not important to model
the stresses placed upon the stamp tool. Therefore, the mesh quality of rigid tooling is less important
in the comparison of the captured shape of the tools.
The R-Mesh macro directly accesses the AutoMesh/rigid body mesh feature. You can find the R-Mesh
macro under both the RADIOSS One Step and Incremental_RADIOSS user profiles.
1. From the File menu, click Open.
2. Select the automesh_ready.hf file and click Open.
3. From the Mesh menu, select R-Mesh.

4. Modify Maximum edge length = 15.0.

Note: The fillet angle field is used to specify a maximum angle across which elements can be
maintained. If at any time two adjacent elements’ normals would exceed this angle,
HyperForm creates a new set of nodes between them to maintain clean feature lines. Using
a higher value would result in nodes spanning along the feature line.

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5. Click Mesh.
6. Click surfs >> displayed.
7. Click proceed.
8. Click Close to close the panel.
9. From the File menu, select Save As and enter the file name as automesh_R_mesh.hf.
10.Click Save.

Step 9: AutoMesh – Re-mesh an existing local mesh

AutoMesh enables you to re-mesh elements. In HyperForm, you can remesh elements when no
geometry exists.
The remeshing function is activated when you switch the entity selector from surfs to elems. Elements
are remeshed with the use of the HyperMesh inferred surface algorithm, if geometry for the selected
elements needs to exist in the model. The inferred surface algorithm interpolates geometry data from
the selected elements in order to create new mesh.
When elements are selected to be remeshed, there is the break connectivity option and the vertex
angle parameter. The break connectivity option detaches the node connectivity between adjacent
selected and unselected elements. This allows you to adjust the node densities along the boundary of
the selected elements. The vertex angle parameter defines the placement of vertices along the
boundary of the selected elements. If the angle between two adjacent element edges along the
boundary is less than the specified angle, a vertex is placed at the meeting point of the two edges.
Anchor nodes create the effect of a fixed point on the inferred surface (which is derived from the
existing mesh) and keep the location of the anchor nodes intact.
1. Click File > Open.

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2. Select the Bpillar_AutoMesh_remesh.hf file and click Open.
3. Click Mesh > AutoMesh.
4. Change the entity selector from surfs to elems.
5. Click elems >> by sets.
6. Check refine and click select. Notice that a set of elements are highlighted.
7. Input element size = 1.0 and make sure break connectivity is selected.
Also verify that all the settings are as shown in the image below:

8. Click mesh to refine a local region and click return. Review the result, as shown in the image
below.
You are still in the Mesh panel.

In the next few procedures, you will rebuild the mesh’s transitional region by re-meshing elements
with applied anchor nodes.
9. Click elems and graphically select elements as shown in remesh region in the image below.
10.Click nodes and graphically select nodes as shown in anchor nodes in the image below.
11.Toggle break connectivity back to keep connectivity.

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12.Click mesh and click return. Notice the mesh transition is re-built, as shown in the image below.

13.Click return to close the panel.

Step 10: Equivalencing nodes

To ensure connectivity between the elements, you need to equivalence any coincident nodes in the
model. The equivalence operation identifies any location where two or more nodes exist within the
specified search tolerance. During equivalence, one of the nodes is retained, and any element
definitions referencing the other nodes are re-defined to use the retained node.
1. Click Mesh > Check > Components > Edges.
2. Click comps and select component by clicking any element on screen.
3. Click select.
4. Input tolerance = 0.2. (This specifies the minimum coordinate distance between two nodes.)
5. Click preview equiv. This identifies duplicated nodes and highlights them with a circle. The nodes
that preview equiv displays can be equivalenced.

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6. Click equivalence to merge coincident nodes.
7. Click return to close the panel.
You have fixed the connectivity problem of one side of the refined region. The remaining
connectivity problems can be fixed using the same technique. For the purposes of this tutorial, you
will load the final result for reviewing directly.
8. From the File menu, select Open.
9. Select the Bpillar_AutoMesh_remesh_final.hf file and click Open.
10.Review the final result.

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HF-0400: Mesh Quality

It is always a good practice to check the quality of the mesh before running the analysis. HyperForm
allows you to check different quality criteria such as conformance to the surface topology, Jacobian,
warpage, length, skew angle, etc. Conformance to surface topology is a visual check that ensures that
the mesh lies on the surface and none of the elements are warped. Checks should be done to ensure
that features are being reasonably captured (fill plot check). Mesh connectivity is equally as important.
This can be checked using the edge check macro.
In general, the below element quality will be satisfied to acquire better analysis result accuracy:
Maintain connectivity
Remove duplicate elements
Avoid zero-length elements (recommended value larger than 0.1)
Warpage is recommended to be less than 30
Larger Jacobian values are better. No negative Jacobian value is allowed. It is recommended to
have a Jacobian value larger than 0.1.

Exercise: Mesh quality checking and improving

This exercise uses the model file mesh_quality.hf.

Tools

The tutorial uses the Element Quality Report module and the following menu options:
Mesh > Check menu:
Elements > Check Elements
Elements > Quality Index
Components > Edges

Mesh > Edit menu:

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 Elements > Combine Elements
Elements > Split Elements

Step 1: Load the model file

1. From the File menu, select Open.

2. Browse to the file <installation_directory>\tutorials\mfs\hf\1Step\mesh_quality.hf.
3. Click Open.

Step 2: Review the 2D mesh quality report

1. From the Utility menu, under Model, click on Check Elems.

2. Click Quality Report. The 2D Element Quality Report dialog appears. The Quality Report Tool will
check all the 2D elements regardless of whether they are displayed on or off.
3. Modify the following values:
Warpage > 30.0
Length < 0.1
Jacobian < 0.1
4. Click Check.

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 Warpage > 30.0 => # of failed Elems = ______________
Length <0.1 => # of failed Elems = ______________
Jacobian < 0.1 => # of failed Elems = ______________
5. Click Close to close the dialog.

Step 3: Check connectivity

1. Click Mesh > Check > Components > Edges.

2. Ensure the comps button is highlighted and graphically pick any element to select the
component.
3. Set the tolerance = 0.01 and toggle to find: free edges.
4. Click find edges. HyperForm generates a new ^edges component. Notice red 1D edge elements
are generated along the free boundary.
5. Using the Model browser, expand the Component folder and uncheck all geometry except the
^edges component.

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 You should see only the red lines for the free mesh boundary. In the next step, you will find
elements attached to the ^edges elements to visually verify this.
6. Click return to close the panel.
7. Click Shift + F5 to open the Find Attached Entities panel. Select the find attached subpanel.
8. Click elems >> displayed.
9. Click find. Repeat steps 8 and 9 again to find 2 layers of elements attached to the edge elements.
Note: Two layers of elements attached to ^edges elements are displayed back on screen. You
can click Find Attached more times to find more layers of elements. Any missing holes or
elements can be indication of connectivity problems. This method can be used to localize
the disconnecting areas.
10.In the Model browser, right-click on the Component folder and select Hide to turn off the display
of all components.
11.Right-click again and select Show to display all components back on screen.
12.Click return to go back to the main menu.
13.In the Model browser, right-click on the ^edges component and select Delete.
14.Click Yes to confirm the action.

Step 4: Visually review the mesh quality

1. From the toolbar, click the Shaded Elements and Mesh Lines icon and select Feature Line
mode .

2. From the toolbar, left-click the Dynamic Rotate icon and move the mouse cursor to the
graphics region and randomly rotate the model for reviewing. Notice two shaded areas as indicated
in the image below. Those areas are indications of elements with poor quality. (You can also use
the User Views icon and retrieve the saved views view1 and view2 to review them.)

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 Shaded areas

3. From the toolbar, click the Shaded Elements and Feature Lines icon and switch to Shaded
Elements and Mesh Lines .
4. Visually review the two areas again with the mesh line displayed. Notice the mesh quality
problem.

Step 5: Manually split an element using the Split panel

In this step, you will use the split subpanel to manually fix an element quality problem. Four methods
used to split elements free-form are illustrated below.
HyperForm prompts you to build a line to split these elements using one of the four methods. Draw a
window as shown in the figure below.

Types of element splits

1. On the keyboard, click V and click restore1 to retrieve a saved view.

2. Click the F6 key to access the Combine Elements panel.
3. Select the split subpanel and change the selector from displayed elems to elems.
4. With elems activated, graphically select the element as indicated in the image below.
5. Under Splitting line:, click points to draw a line passing through two nodes (two black circles in

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 the image) of the selected element. Refer to the image below.
6. Click split to split the element.

Step 6: Use the Check Elements panel

1. Click F10 to open the Check Elements panel.

2. With 2-d selected, click duplicates to check if there are any duplicated elements. The message
bar displays "0 duplicate elements were found". If any duplicate element is identified, it will be
highlighted.
3. Click length. The message bar warns that the minimum length is larger than 0.0. Any element
with length equal to or less than 0.0 must be fixed.
4. Click jacobian. The message bar warns that the minimum length is larger than 0.0. Any element
with Jacobian value equal to or less than 0.0 must be fixed.
5. In the warpage field, enter 30.0.
6. Click warpage. Notice that the message bar displays "25 of 4668 (1%) failed. The maximum
warpage is 176.01."
7. Click save failed to store the failed elements (warpage > 30.0) into a user mark. The message bar
displays "The highlighted elements have been placed in the user mark".
8. Click return twice to close the panels.
9. In the Model browser, right-click on the Component folder and select Hide.
10.Press Shift+F5 on the keyboard to open the Find panel.
11.Open the find entities subpanel. Click elems and select retrieve to retrieve elements from the
user mark. The message bar displays "25 elements added by ‘retrieve. Total selected 25".
12.Click find to display the 25 elements on the screen. Elements with warpage >30.0 are displayed
on the screen.
13.Press the F key to fit the model to the screen.
14.Click return to close the panel.

Step 7: Display all elements

1. Click Shift+ F6 key to open the Edit Elements panel.

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2. In the plate elements subpanel, click the selector to change from split all sides to divide quads.
3. Click elems >> displayed.
4. Click split. The displayed quad elements are divided into trias elements.
5. In the Model browser, right-click on the Component folder and select Show.

Step 8: Use the Quality Index

1. Click Mesh > Check > Elements > Quality Index.

2. Under pg1 (page 1), uncheck max size, aspect ratio and skew.
3. Under threshold, input min size = 0.1 and warpage = 30.0.
4. Click right next to pg1 and change to pg2.
5. Uncheck all features EXCEPT # of trias.
Notice elements with color on screen indicate they fail to satisfy the activated quality check.
Quality Index function allows element's quality to be improved by node optimize method and
element optimize method.
- For node optimize method, click node optimize and select a node on the screen. HyperForm
repositions the node on the inferred surface to obtain the best possible quality for all elements
attached to that node.
- For element optimize method, click element optimize and select an element on the screen.
The locations of all its nodes move on the inferred surface to obtain the best possible quality
for that element and its neighbors.
In this, you will leave Jacobian = 0.3 .
6. On the keyboard, click V and click restore 3 to retrieve a saved view.
7. Click node optimize and graphically pick the node as indicated in the image below.

Notice the selected node is relocated and element quality is improved. The associated element is
also changed to transparent mode.
8. Click return.

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Step 9: Compare 2D mesh quality improvement

1. Click Applications > RADIOSS One Step.

2. From the Utility menu, under Model, click on Check Elems.
3. Click the Quality Report macro.
4. Modify the following
Warpage > 30.0
Length < 0.1
Jacobian < 0.1
5. Click Check.
6. Compare the values to the ones written in step 3.
7. Click Close to close the dialog.

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HF-0500: Model Preparation - Undercut Check and Autotipping

Undercut is a term used in part design that refers to situations that lead to die lock condition when the
part is being formed. In real-time forming applications, parts are designed in such a way that they get
locked if formed. Split dies and punches with negative rake angles are used to form such parts to avoid
this situation. But for the simulation purpose in One-Step analysis, the part is tilted in such a way that
the Z-axis of the part matches with the Z-axis of the punch and the die. This process of aligning the
part axis with the tool axis is called Autotipping. The angle to be tilted is calculated automatically by
HyperForm.
Stamping can also be done in any of the three principal axes or an arbitrary axis in space by using
the stamping direction subpanel in the Autotip panel.
The autotipping option will reduce the draw depth by making the z-axis as the stamping direction.
In this tutorial you will learn to check for undercut and remove it in a part by using the Autotip feature.
This tutorial assumes that you are familiar with functionalities such as creating components, geometry
cleanup, and meshing. Information on these topics can be found in the online help.

Exercise: Undercut checking and Autotipping

This exercise uses the model file mesh_quality.hf.

Tools

The tools used in this tutorial can be found in the RADIOSS One Step user profile.
Autotipping
Allows you to set the user defined stamping direction for the part. It can also help you to tip (orient)
the part in the formable position along the user defined stamping direction.

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Undercut check panel
Allows you to identify all the elements in the displayed part that may lead to a die-lock condition. The
stamping direction is assumed to be along the global z-axis.

Step 1: Load the model file

1. From the File menu, select Open.

2. Browse to the file <installation_directory>\tutorials\mfs\hf\1Step\mesh_quality.hf.
3. Click Open.

Step 2: Check the undercut in the part

1. Click Tools > Undercut Check.

2. Click comps and select the mesh component.

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3. Click check undercut.
Notice that the header bar displays the number of elements with an undercut problem. Any
element detected with an undercut problem is highlighted on screen. You can click saved failed
and save the undercut elements into a user mark to be retrieved and fixed later.
In One-Step analysis, minor undercut problems occurring at non-critical areas are unavoidable and
acceptable. When significant undercut is detected, Local bending/Unbending in the Advanced
panel is automatically disabled for better result accuracy.
In this exercise, the undercut problem is not severe and therefore you will leave the model as it is.
4. Click return.

Step 3: Autotip the model

1. Click Tools > Autotipping.

2. Select the autotip subpanel.
3. Verify the entity selector is set to comps and select the mesh component.
4. Verify the toggle is set to full model and keep the rest of the options as default.
5. Click calc autotip. Notice the angle to be tilted is displayed on the header bar.
6. Click autotip. This action will tilt the part by an angle calculated by HyperForm to avoid the die
lock situation during forming. The default tipping direction would be +Z. Click F to fit the model to
the screen if the display is not desirable.

Step 4: Autotip the model along a user defined plane

1. Click the stamping direction radio button.

2. Click on the vector selector and select the N1 N2 N3 option.

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3. Click on any 3 nodes as shown below along the tail of the part and click set.
4. Open the autotip subpanel.
5. Verify the entity selector is set to comps and select the mesh component.
6. Verify the toggle is set to full model and keep the rest of the options as default.
7. Click calc autotip. The angle of orientation is displayed on the header bar.
8. Click autotip.
Note: Similarly the tool tipping can performed as per the user specific requirements.

N1 N2 N3 node selections

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HF-1000: One-Step Stamping Simulation

In this tutorial you learn how to:

Import geometry data
Clean up geometry
Create a finite element mesh
In preparation for running the model, you specify blankholders and set constraints. After running the
analysis, you view the results in a contour plot, blank shape, and FLD contour.

Exercise: Basic Draw Forming Analysis

This exercise uses the model file part1a.igs.

The imported part is considered to be clean. No free edges are present and all of the edges are stitched.
However, many small surfaces are present in the part. The following steps show you how to minimize
the number of these surfaces.

Tools

This tutorial uses the following panels available in the RADIOSS One Step user profile:
Remove Holes panel
Mesh panel
Component panel
Constraints panel
Blankholder panel
Blank Shape panel
Formability panel

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Step 1: Import the model file

1. From the File menu, select Import Geometry.

2. Click the Select Files icon and browse to the file <installation_directory>\tutorials\mfs
\hf\1Step\part1a.igs.
3. Click Import, and then click Close.

Step 2: Save a HyperForm data file

1. From the File menu, click Save As.

2. Enter the file name and extension as part1a.hf.
3. Click Save.

Step 3: Change the component color

1. In the Model browser, expand the Components folder.

2. For the components lvl1 and lvl7, click the colored box to select a color of your choice.
Notice the color of the components has changed.

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Step 4: Suppress lines

1. From the toolbar, select Geometry > Edit > Surface Edges > (Un)Suppress.
2. Click lines and select all from the pop-up menu.
3. Click suppress. This suppresses all of the internal edges that are shared by the surfaces and
converts the model into one big surface.
Stay in the same panel for the next step.

Model after lines have been suppressed

Step 5: Add fillet features

1. Click lines again, and select the suppressed lines, as shown in the image below.

2. Click unsuppress. The selected blue lines become green lines to define the corner of the fillets.
(Green lines can be noticed when toggled to By Topo.) Later when you are meshing, node seeding
can be generated along the green lines for better mesh quality control.
3. Click return.

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 Edges to be unsuppressed prior to meshing

Step 6: Remove a hole from the surface

1. Click Geometry > Defeature. On the left of the panel, select the pinholes radio button.
2. Click the yellow surfs button. The surfs button is outlined in cyan indicating that it is active.
3. On the model graphics, click the flat surface.
4. Click the pinholes button and select all.
5. Enter 40 in the diameter field.
6. Click find.
7. Notice the xP display on screen indicating a pin hole has been identified with a diameter less than
40.
8. Click delete.
9. Click return.

Step 7: Create a finite element mesh

1. Click Mesh > AutoMesh.

2. Click surfs >> displayed.
3. Use the settings below:
Toggle is set to interactive
Element size = 7
Mesh type = mixed
Toggle is set to elems to current comp

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 Toggle is set to first order
Switch is set to break connectivity
Size and skew are selected
4. Click mesh.
5. Click return twice to close the panel.

Step 8: Load the material library

1. Click Setup > Materials and select the library subpanel.

Notice default material types are provided under Materials in file.

2. Verify that CRDQ steel is loaded under Materials in memory. If not, click >> and load CRDQ
steel under Materials in memory.
3. Click return.

Note: The default material for one-step solver is located at

[HyperWorks installation] /hm/scripts/hyperform/
hf.mat. You can edit this file and store user-defined material
data into this library.

Step 9: Create and update the elements to the component

1. Click Setup > Components.

2. Click Component: and enter Part.
3. Click Material: and select CRDQ Steel.
4. If you created an FLD curve, click FLD curve and select the curve. Otherwise, leave it blank, and
HyperForm will automatically create an FLD curve.
5. Click thickness= and enter 1.
6. Select a color.
7. Click create to create the component.

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8. Click elems and select all elements to be defined in the part component.
9. Click move.
10.Click update.
11.Click return.

Step 10: Set constraints

1. Switch to shaded mode by clicking on this button from the header bar:
2. Click Setup > Constraints.
3. Click nodes and select on plane.
4. Set the direction selector to x axis.
5. Click B.
6. Pick a point on the symmetric plane, as shown in the image below.
7. Click select entities.
8. Below Constraint Type, click X.
9. Click size= and enter 10.
10.Click update.
11.Click return.

Constraints along the symmetric edge

Step 11: Specify a blankholder

Blankholders can be defined as the upper and lower holding surfaces that control metal flow around a
shape to be formed in a draw operation. They supply a restraining force on the material during the
pressing process.

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HyperForm allows you to define the blankholder force in two ways: on element and on edge. The
correlation between the magnitude and level of the applied forces is always available. Edge
blankholder force application allows you to restrain an edge by enabling automatic selection of all
nodes between two user-defined nodes along a free edge of a part.
You can define the blankholder force in two ways: tonnage force or pressure level (high, medium and
low).

Note: The pressure level is proportional to the area of blank under

the blankholder as well as thickness. A pressure level of 2MPa,
5MPa and 10MPa for a 1mm blank has been chosen as a
reference for Low, Medium, and High (based on practical
experience). The tonnage (metric ton unit) is equivalent to the
pressure times the blankholder area normalized/scaled by the
thickness (1 metric ton = 9810N).

1. Click Setup > Blankholder.

2. Click blankholder and type Blankholder 1.
3. Set the pressure level to low.
4. Click friction = and enter .125.
5. Click elems >> on plane.
6. Toggle the switch to z-axis and pick a node on the binder (flat region) for B (base node).
7. Click tolerance = and enter .3.
8. Click select entities.

Select elements on the binder region

9. Click color and select a color of your choice.

10.Click create.
You can see the corresponding tonnage force in the tonnage= field.
11.Click return.

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Step 12: Save the file

1. Click File > Save As.

2. Enter the file name as part1a_complete.hf.
3. Click Save. This saves the file in the current working directory. The Save as… option can be used
to save the file at the desired location.

Step 13: Run the analysis

1. Click Setup > Run Analysis.

2. Click project: and select the saved file part1a_complete.
3. Click run analysis.
4. Click view output.
5. Click 1- to review information about the analysis.
6. Click view output again.
ASCII result output information is displayed.
Notice estimated press tonnage = 0.406E+02 (tons).
7. Click close to close the summary.

Step 14: View the results

1. Click load results while in the same panel.

2. Click return to exit the Run Analysis panel.
3. Press D on the keyboard and click the toggle switch to loadcols. Click on None to turn off the
display of constraints.
4. In the Model browser, expand Components and click on the Geometry icon for each
component to turn off the geometry display.
5. Click Tools > %Thinning.
6. When you are finished viewing results, click return.

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 Contour plot showing % thinning

Step 15: View the blank shape profile

1. Click Tools > Blank Shape.

2. Select Initial to display the minimal blank shape.
3. Select Final to view the original part geometry.
4. Click return.

Step 16: View the forming limit diagram

1. From the Utility menu, under Results, click Formability.

2. Click component, and then on the model graphics select the Blank component.
3. Click Create FLD.
4. Pick a point on the curve that represents a corresponding element on the model, or pick an
element on the model. The corresponding major (y) and minor (x) strain are displayed in the
header bar.

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Forming Limit Diagram of part1a

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HF-1010: Increasing Blankholder Pressures

In this chapter, you will learn how to increase blankholder pressure and compare the results from
different pressure levels. The result from the previous tutorial, One-Step Stamping Simulation (HF-
1000), will be used to compare the result from this tutorial.

Exercise: Increasing Blankholder Pressures

This exercise uses the model file Blank_holder.hf.

Tools

This tutorial uses the following panels, which are available in the RADIOSS One Step user profile:
Blankholder panel
Blank Shape panel
Formability panel

Step 1: Load the model file

1. From the File menu, click Open.

2. Browse to the file <installation_directory>\tutorials\mfs\hf\1Step\blank_holder.hf.
3. Click Open.

Step 2: Edit the blankholder and save as a different file name

1. Click Setup > Blankholder. The blankholder parameters are already set up from the previous run.
2. Click blankholder and select Blankholder 1.
3. Set the pressure level to High.

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 Notice value in tonnage = is changed from 21.127 to 105.634.
4. Click update.
5. Click return.
6. From the File menu, click Save As.
7. Enter the file name as blank_holder_complete.hf.
8. Click Save.

Step 3: Run the analysis

1. Click Setup > Run Analysis.

2. Verify project = is set to blank_holder_complete.
3. Click run analysis.
4. Click load results when your job has finished.
5. Click return.

Step 4: View the forming limit diagram

1. Click Tools > Formability.

2. Click comps and select part.
3. Click create FLD.

Note: Pick a point on the curve (which represents a corresponding

element on the model) or pick an element on the model. The
corresponding major (y) and minor (x) strain are displayed in
the header bar. The corresponding element ID is also
displayed in the Formability panel.

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4. Click return.

Step 5: View the thinning

1. Click Tools > Thinning.

2. Click Contour.

3. Click return to close the panel.

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HF-1020: Applying Drawbeads and Performing Circle Grid Analysis

In general, the material flow is controlled by the blankholder and a resultant restraining force is created
by friction between the tools and the blank. However, during a forming process, it is common that a
blankholder does not make contact with an entire blank. Therefore, material flow is usually not fully
controlled by the blankholder.
When a high restraining force is required, a higher blankholder force must be applied, which could cause
wear in the tools. A local control mechanism is therefore necessary to restrain the material flow
sufficiently at relatively low blankholder pressure. This is achieved by applying drawbeads.
The drawbead creates a restraining force by cyclically bending and unbending the sheet as it traverses
the drawbead, causing strain hardening and a change in the strain distribution with consequential
thinning of the blank.
HyperForm lets you define a restraining force for the drawbead in two ways: qualitative (pressure level)
or quantitative (restrain force). You can also define a lockbead, which will apply a 100 percent
restraining condition.
HyperForm provides drawbead function both for One-Step and Incremental analysis. The interface of
the Drawbead panel is switched automatically based on the currently-selected analysis type.
In this tutorial, you will learn to define drawbeads for One-Step analysis. You will also use the Circle Grid
panel to show relative magnitudes and associated direction of major and minor strains.
This tutorial uses the Drawbeads panel, Run Analysis macro and the Circle Grid panel.

Exercise 1: Applying Drawbeads to a Model

This exercise uses the model file drawbead_1step.hf.

Step 1: Load the model file

1. From the File menu, click Open.

2. Browse to the file <installation_directory>\tutorials\mfs\hf\1Step\drawbead_1step.hf.
3. Click Open.

Step 2: Add a drawbead to the existing model

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1. Click Setup > Drawbeads.
2. Select the restrain radio button.
3. Click drawbead and type Drawbead1.
4. Pick a drawbead condition: force level = medium.
(High is 80 percent, Medium is 50 percent and Low is 20 percent of necking condition).
5. Click the color button, and then select green from the color palette.
6. With the halo surrounding node list, pick two nodes on the blank as indicated in the image
below to define the drawbeads.

7. Click create. A message shows "The drawbead set has been created". A line is created
representing drawbeads.

Step 3: Update drawbeads using the calculate subpanel

Modeling the exact drawbead geometry requires a large number of elements, which increases CPU
time dramatically. A practical approach is to use an equivalent drawbead model by representing the
drawbead analytically and providing a constant drawbead restraining force and closure force.
Use the calculate subpanel to determine the closure and restraining force based on drawbead
dimensions. The restraining force is the value of the force (per unit length) applied by the bead in
the plane of the blank surface. The closure force is the force (per unit length) required in the
perpendicular direction to keep the drawbead closed.

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1. Select the green calculate button.
2. Click material: and select the current blank material (CRDQ steel).
3. Verify that the drawbead height, shoulder radius, and drawbead radius are set to 6.25.
4. Click calculate. Notice that the output restraint force, closure force and necking result are
calculated accordingly.
5. Click update to go back to the Drawbeads panel. If the geometry is such that a necking
condition exists, the message, Material Locking Condition is displayed on the status bar.
6. Click update.
7. Click return.

Step 4: Save and run the analysis

1. From the File menu, click Save As.

2. Enter the file name as drawbead_1step_complete.hf, and then click Save.
3. Click Setup > Run Analysis.
4. Make sure project: is set to drawbead_1step_complete.hf.
5. Click run analysis.
6. Click load results when your job has finished.
7. Click return.

Step 5: View the thinning contour plot

1. Click Tools > % Thinning to view the thinning contour plot.

2. Click contour to review the result.

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 3. Click return to close the panel.

Step 6: Review the Forming Limit Diagram

1. Click Tools > Formability.

2. Select the Part component.
3. Click Create FLD, and then click FLD contour.
4. Click return.

Exercise 2: Performing Circle Grids Analysis

This exercise uses the result from Exercise 1, drawbead_1step_complete.hf.

In circle grid analysis, a sheet of metal is prepared by etching a circle grid onto the surface. Plastic
deformation in the steel during the forming operation causes the circles to deform into ellipses. The
plastic strain at each circle is then calculated from the major and minor diameters of the ellipses.
In HyperForm, the Circle Grid panel allows you to show relative magnitudes and associated direction
of major and minor strains with respect to deformed mode by displaying circles drawn on the blank
surface. A result file needs to be loaded before performing circle grid analysis.
Step 1: Review circle grids

1. Click Tools > Circle Grid.

2. Pick the elements you want to display.
3. Select Initial Circle to show the initial status of the blank.
4. Select Deformed Circle to show the final deformed status of the blank.
5. Set the switch to cir & dir, cir only, or dir only to show the circles and/or major and minor
deformed direction.
6. Click draw. The circle grid is displayed. If you change the display method, click draw again to
refresh the screen.
7. To clear the circles and/or directions, click clear.
8. Click return to close the panel.

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 Circle grids on initial and deformed blanks

Step 2: Press tonnage output

The HyperForm solver also outputs the estimated press tonnage required to form the part. The
press tonnage is written out in the output file.
1. Click Setup > Run Analysis.
2. Click view output.
3. Select 1- to view the text in graphics area. Scroll down toward the bottom. The estimated press
tonnage output can be seen as shown in the figure below.
4. When finished, click Close to close the report, and click return to close the panel.

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HF-1030: Transferring Forming Results to Crash Analysis

HyperForm One-Step analysis can generate a LS-DYNA input file (a dynain file) containing forming
results. This effectively allows users to initialize a crash model with forming effects. The preferred
quantities to be used for forming initialization are thickness and plastic strains (the stresses are set to
zero).
This tutorial features the procedures for preparing an input file for a crash simulation, and illustrates
how to:
Perform autotipping on the model
Perform undercut checking
Create a dynain file using the HyperForm One-Step solver
Position the stamped part into a car coordinate position
Export the stamped part for use in a crash simulation
This tutorial uses the following panels:
Autotipping panel
Undercut Check panel
Advanced panel (Dyna/Nastran output option)
Position tool (Mesh menu)

Exercise: Transferring Forming Results to Crash Analysis

This exercise uses the model file bumper_car_coordinates.hf.

Step 1: Load the model file and change the model orientation

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1. From the File menu, click Open.
2. Browse to the file <installation_directory>\tutorials\mfs\hf\1Step
\bumper_car_coordinates.hf file.
3. Click Open.
The structure part (bumper_car_coordinates.hf) is not oriented with respect to the stamping
direction (z-axis). Prior to running the forming simulation and transferring the forming to the part
in a crash simulation, it must be re-oriented with respect to the z-axis. Refer to the image below.

Step 2: Autotip the model

1. Click Tools > Autotipping.

2. Select the autotip subpanel.
3. Click comps and select the bump_car_co-ord component.
4. Click select.
5. Verify that the toggle is set to full model.
6. Click calc autotip. The message bar displays the potential rotation angles for autotipping with
respect to the stamping direction (z-axis).
7. Click autotip.
8. Click the F key on the keyboard to fit the model to the screen.
9. Click return to close the panel.

Step 3: Perform undercut checking

1. Click Tools > Undercut Check.

2. Click comps and select the bump_car_co_ord component.
3. Click the green check undercut button. Notice no elements get highlighted on the screen. The
model passes the undercut check and no problems are detected.

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 Note: A set is created when perform undercut checking. You will
delete the set before solving the problem in One-Step
analysis.

4. Click return to close the panel.

5. In the Model browser, expand the Set folder and right-click on the hf_undercut_set set.
6. Click Delete and select Yes to confirm the action.

Step 4: Request LS-DYNA/Nastran output format

1. In this step, you will request output format in LS-DYNA and Nastran solver formats for forming
analysis. This allows HyperForm to write out a results file that can be directly used to initialize a
structural analysis model. The names for the output files are:
[filename]_thk.nas and [filename]_dyna.k corresponding to Nastran and LS-DYNA solvers,
respectively.
[filename]_thk.nas contains the mesh data along with the nodal thickness.
[filename]_dyna.k contains the mesh and the nodal thickness, followed by the stress tensor
and plastic strain at each integration point within an element.
2. Click Setup > Advanced.
3. Click RADIOSS/Dyna/Nastran output. This option will take you to another panel.
4. Toggle the option to w/o stress (zero stress will be written to the dynain file).
5. Click comps.
6. Click comps again and check the bump_car_co-ord component.
7. Click select.
8. Click return twice to close the panels.

Step 5: Save the file

1. From the File menu, click Save As.

2. Enter the file name as bumper_car_coordinates_complete.hf and click Save.

Step 6: Run the analysis

1. Click Setup > Run Analysis.

2. Click project: and select bumper_car_co_ordinates_complete.

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3. Click run analysis.
4. Click return when the analysis is finished.
Note: Notice several files are generated when 1 step analysis is finished:
bumper_car_co_ordinates_complete.parm : HFSolver Input deck generated by HyperForm.
bumper_car_co_ordinates_complete_dyna.k : Contains the mesh and the nodal thickness,
followed by the stress tensor and plastic strain at each integration point within an element.
bumper_car_co_ordinates_complete_thk.nas : Contains the mesh data along with the nodal
thickness.
bumper_car_co_ordinates_complete.out : ASCII output file contains model and run information.
This file can be used to debug model and system level problems.
bumper_car_co_ordinates_complete_opt.dat : Input deck for optimization runs with HyperStudy.
bumper_car_co_ordinates_complete.dat : Input data summary.

Step 7: Delete the current session and load the resultant DYNAIN file with the
forming result

1. Press F2 to open the Delete panel.

2. Click delete model.
3. Click yes to confirm deletion of model.
4. Click Applications > Incremental LS-DYNA to change the user profile.

5. From the File menu, click Import > Solver Deck .

6. Click the folder icon and browse to the location where the previous analysis was run to select
the file bumper_car_co_ordinates_complete_dyna.k.
7. Click Open to select the file.
8. Click Import to import the file and Close to close the dialog.
The output file bumper_car_co_ordinates_complete_dyna.k has the identical format as the LS-
DYNA DYNAIN file. During the import of the *_dyna.k (dynain) file, only the node and element
definitions are read into HyperForm. The initial stress and plastic strain quantities are
automatically placed into a new file with an .hmx extension (i.e. filename_dyna.k.hmx) and
HyperForm automatically activates an INCLUDE control card to retain the information. More detail
regarding DYNAIN file will be discussed in HyperForm incremental analysis.
Notice the warning message "No renumbering or rotation is allowed. Stress and strain history will
get written to a .hmx file. Continue?"
9. Click Yes.
If the *_dyna.k (dynain) file contains stress quantities, no rotations of the component are allowed.
The stress tensors are written with respect to a global coordinate system, and would require a

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 suitable transformation. In this exercise, because the file contains zero stress, rotations of the
component are allowed.

Step 8: Position a stamped part back to car coordinate position

In this step, you need to orient the model *_dyna.k file (dynain file) which has the information from
the One-Step forming run, back to the car co-ordinate system model for crash analysis. You will first
import the original bumper_car_coordinates.hf and re-position forming result in z-axis (*_dyna.k
(dynain) file) back to the original vehicle coordinate.

1. From the File menu, click Import > Model .

2. Click the folder icon . In the file browser dialog, switch the Files of Type field to All Files.
3. Select the bumper_car_coordinates.hf file.
4. Click Import.
5. Click the F key on the keyboard to fit the model to the screen.
6. Click Mesh > Position > Components.
7. Click the selector and choose comps.
8. Click comps.
9. Check the 1 component (import from *_dyna.k file) and click select.
10. Click from: N1, N2, and N3 and select three nodes on the part in forming coordinates (part in
gray color) as shown below.
11. Click To: N1, N2, and N3 and select three nodes on the part in car coordinates (part in blue color)
as shown below.
Note: The locations and selection sequence of N1, N2 and N3 nodes in "from" will need to
exactly match the corresponding N1, N2 and N3 nodes in "To". This ensures the
transformation (consisting of translations and rotations) that maps the differences between
the two sets of nodes is applied to the selected entities until they are relocated.

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12. Click position to reorient the stamped part back to car coordinate position. Notice two models are
overlapped with each other.
13. Click F2 to jump to the Delete panel.
14. Change the selector to comps.
15. Click comps again and select the bump_car_co-ord component.
16. Click select.
17. Click delete entity. The original part in vehicle is deleted.
18. Click return twice to go back to the main menu.

Step 9: Export the model as a new LS-DYNA input file

1. From the File menu, select Export.

2. Verify the template field is set to LS-DYNA.key (LS-DYNA template).
3. Click File: and type the name bumper_crash_input.key.
4. Click Export and click Close.

Step 10: Review the LS-DYNA input file and the *.hmx file

1. Open any text editor and load the bumper_crash_input.key file for reviewing.
Notice:

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A. The dyna input file contains the thickness distribution from the One-Step analysis.
*ELEMENT_SHELL_THICKNESS
$ EID PID N1 N2 N3 N4
13 2 12 21 23 14
1.00013 1.00026 1.0004 1.00036
14 2 21 22 24 23
1.00026 1.00045 1.00038 1.0004
15 2 14 23 25 16
1.00036 1.0004 1.00073 1.00097
………………………………
………………………………

B. Plastic strains are carried and included in the *_dyna.k.hmx file

*INCLUDE
[ full path ] / bumper_car_coordinates_complete_dyna.k.hmx

C. bumper_car_coordinates_complete_dyna.k.hmx contains residual strain data from the 1Step

forming analysis.
*INITIAL_STRESS_SHELL
*INITIAL_STRESS_SHELL
$ EID NPLANE NTHICK
$ T SIGXX SIGYY SIGZZ SIGXY SIGYZ SIGZX EPS
Where "EPS" is Effective Plastic Strain

D. Forming related control cards need to be deleted/modified accordingly before running the crash
analysis
*CONTROL_SHELL
*CONTROL_HOURGLASS
*CONTROL_BULK_VISCOSITY
*CONTROL_CONTACT
*CONTROL_PARALLEL
*CONTROL_ENERGY
*CONTROL_ACCURACY……

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HF-1040: Laser Weld

A laser-welded blank consists of different thicknesses of metal that has been laser-welded together into
a sheet. In addition to achieving direct cost reductions through the more efficient use of materials,
tailored blanks also offer manufacturers the potential for greater flexibility in design. Manufacturers
currently apply several types of joining processes to weld coated-steel tailored blanks such as seam
welding, high-frequency welding, electron beam welding, and laser welding.
In this tutorial you will learn to simulate the welding of two blanks with different thickness and material
properties.
To set up the analysis for a laser weld, you need to define two (or more) components in the supplied
model. The components may be assigned to different materials and may have different thickness and
FLC curves. You use a default FLC curve for one component and create a user-defined FLC curve for
another component. In the next step, you will create a sample FLC curve using minor and major strain
data.

Exercise: Laser Welded Blank

This exercise uses the model file laser_weld.hf and Laser_weld_FLC_curve.csv.

Tools

This tutorial uses the following panels:

FLD Curves panel
Component panel
Save panel
Run panel

Step 1: Load the model file

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1. From the File menu, click Open.
2. Browse to the file <installation_directory>\tutorials\mfs\hf\1Step\laser_weld.hf.
3. Click Open.

Step 2: Load the FLD curve

1. From the Setup menu, click FLD Curves.

2. Click the library subpanel.
3. Click file = and select Laser_weld_FLC_curve.csv.
The figure below shows the FLD curve panel.

On the left-hand side of the panel, under Curves in file, the name of the curve (FLD Curve)
should appear.

4. Click to transfer the FLD curve to memory.

The name FLD Curve should appear beneath Curves in memory.
5. Click return to exit out of the FLD Curve panel.

Step 3: Reorganize the elements into two components

1. Click Mesh > Organize > Elements > To Component and select the collectors subpanel.
2. Click elems and select by windows from the pop-up menu.
3. Draw a window on the graphics area to include the top half of the elements of the entire model.
Refer to the image below.

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4. Click select entities. Notice the elements within the window are highlighted.
5. Click Dest Component = and select comp1.
6. Click move. All selected elements are moved and stored in the comp1 component.
7. Repeat steps 1-6 and relocate lower elements into the comp2 component.
8. Click return.

Step 4: Assign different thicknesses and FLC curves

1. Click Setup > Components.

2. Click component: and select comp1.
3. Click material and select CRDQ steel.
4. Click thickness = and type 1.0.
5. Click update.
Notice the message bar shows "The component has been updated." You have associated the
comp1 component with the CRDQ steel material and a thickness of 1.0.
6. Repeat steps 1 - 5 and re-associate the comp2 component, as shown in the table below:

Component 1 Component 2

Name : comp1 Name : comp2

Material : CRDQ Steel Material : Steel 1
FLD curve : Default_FLC FLD curve : FLD curve
(Blank)
Thickness : 2.0
Thickness : 1.0
Color : color blue
Color : color green

Note: comp1 is assigned the Default_FLC curve (blank) and comp2

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 is assigned the user defined FLD curve.

7. Click return.

Step 5: Run the analysis and post-process the results

1. From the File menu, click Save As.

2. Browse for a user defined location and name the file as laser_weld_complete.hf and click Save.
3. From the Setup menu, click Run Analysis.
4. Click run analysis.

5. Click load results.

6. From the Utility menu, under Results, use all the functionalities for reviewing results.

7. Review the results of the laser-welded blank.

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HF-1050: Trim Line Layout

This feature allows you to track a line between the stamped part and the initial undeformed blank to
minimize material waste (part to blank). It also allows you to map trim lines between the intermediate
stages of stamping such as between the final flanged stage and the prior drawn stage (part to part).
The tutorial is divided into two exercises:
Exercise 1: Trimming the Line Layout
In this exercise, you will study the difference between the final part to the undeformed blank and
generate IGES data for a trim line selected from the part and mapped onto original blank.
Exercise 2: Mapping the Trim Line from Final Part to Intermediate
The purpose of the part-to-part line mapping is to allow you to map a line (or node list) between a
final part and an intermediate part.
This tutorial uses the Line Mapping panel.

Exercise 1: Trimming the Line Layout

This exercise uses the model file part_blanktrimline.hf.

Step 1: Load the model file

1. From the File menu, click Open.

2. Browse to the file <installation_directory>\tutorials\mfs\hf\1Step
\part_blanktrimline.hf.
3. Click Open.

Step 2: Save the file and load the result

1. From the File menu, click Save As.

2. Browse for a user defined location and name the file as part_blanktrimline_complete.hf and
click Save.

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3. Click Setup > Run Analysis.
4. Click run analysis. HyperForm solves the analysis.
5. When the analysis is finished, click load results.
6. Click return to close the panel.

Step 3: Map the trim line on the blank

1. From the main panel area, select the Line Mapping panel and the part to blank subpanel.
2. Click line and select the line on the final part shape as shown in the figure.
Note: This line is the one that will be mapped on to the flat blank.

3. Click comps and select final_part as your flange part:.

4. Click initial to display the original points with respect to the undeformed blank.
5. Click return to close the panel.

Note: The trim line can be exported as IGES data externally.

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Exercise 2: Map the trim line from the final part to the intermediate part

This exercise uses the model file part_parttrimline.hf.

The purpose of the part-to-part line mapping is to allow you to map a line (or node list) between a
final part and an intermediate part. This method can be useful for predicting where a part should be
trimmed prior to a flanging operation.
For example, if you have a part that is made using three operations (1st draw, trim, and 2nd draw),
and you want to predict where the flange line should be trimmed prior to the 2nd draw, you can use
the line mapping (part to part) feature. To do this, you will need to model the part shape at the end of
the 1st draw (intermediate shape) and at the end of the 2nd draw (final shape). Both of these parts
should be modeled in the same HyperForm file. After performing the 1Step analysis and loading the
results file, the line mapping function can be used. The flange line should be defined on the final
shape and trim part elements should belong to the intermediate part.
Step 1: Retrieve the file

1. From the File menu, click Open.

2. Browse the to file <installation_directory>\tutorials\mfs\hf\1Step
\part_parttrimline.hf.
3. Click Open.

Step 2: Review model setup

1. Click Setup > Components to review the two components. There are two components that
represent the intermediate and the final part.
2. (optional) Click the letter D to open the Display panel. Change the entity selection to loadcols
to see how the parts have been constrained. This prevents the parts from moving with respect
to each other.

Step 3: Save the file and load the result

1. From the File menu, click Save As.

2. Browse for a user defined location and name the file part_parttrimline_complete.hf and click

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 Save.
3. Click Setup > Run Analysis.
4. Click run analysis.
5. When the analysis is finished, click load results.
6. Click return.

Step 4: Map the trim line

1. From the main panel area, select the Line Mapping panel and select the part to part option.
2. Pick the nodes or line you want to map as your flange line.
You can select the line in the ^feature component.
3. Click trim: comps and select the intermediate_part component.
4. Click flange part: comps and select final_part component.
5. Click map. A mapped line is generated and stored in the ^Mapping_line component.

Line mapping Part to Part

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Die Module Tutorials

HF-2010: Basic Addendum Creation with the Die Process

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HF-2005: Basic Addendum Creation Using Die Process

Die Process is a browser based approach for creating and editing addendum and eventually the die
cavity.
The addendum is a part of the die face and that facilitates the smooth and controlled flow of the metal
into the die cavity. HyperForm allows you to create the addendum and construct a complete die with the
part profile as the input. First a binder is constructed and the addendum is built connecting the part and
the binder surface. The binder is then trimmed to get a complete die cavity. The addendum can also be
created with different cross sections depending on the complexity of the part shape. You also have the
flexibility of modifying the cross section of the addendum depending on the changes to the part design.

Exercise: Designing an Addendum with a Constant S-Section

Step 1: Load the File

1. From the File menu, click Open....

2. Browse to the file <installation_directory>\tutorials\mfs\hf\die\cup_addendum.hf.
3. Click Open.

Step 2: Define the Die Process Settings

1. On the Die Process tab, under Settings, right-click Symmetry > Edit. The Symmetry Setting
panel appears.

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2. Make sure Symmetry toggle is set to full.
3. Click return.
4. From the toolbar, select Preferences > HyperForm Settings.
5. In the dialog that appears, select the ProcessDefaults tab.
6. For BinderDepth, enter 10.0.
7. For BinderOffset, enter 50.0.
8. Click Apply, then Close.

Step 3: Prepare Part for Die

1. On the Die Process tab, in the tree under Dies > Die1, right-click Part: (none) and select Set....
2. Select the part from the graphics screen and click proceed.
Note that the name of the component appears in front of the label Part:. For this example, Part:
Die1 appears. A copy of the selected part is made in component Die1 to create the die surface.
Also the outer boundary of the part is automatically determined and assigned as the trim line.

Step 4: Create the Binder

1. On Die Process tab, in the tree under Dies > Die1, right-click Addendum Start Line, and then
select Auto.
The addendum start line is automatically added to the component ^Die1_ASL1 and assigned to
the object Addendum start line.
2. Under Dies > Die1, right-click Binder, and then select Create. A new object, Binder1, is created
and the ASL created in the previous step is assigned to it.

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3. Right-click Binder1, and then select Create > From Part:

The binder surface is created in the component Die1_Binder1 and assigned to Binder1.

Step 5: Create the Addendum

1. On the tree of the Die Process browser, under Die1, right-click Addendum, and then select New.
A new object Addendum1 is created and the binder created in the previous step is assigned to it.
2. Right-click Addendum1, and then select Create > From Part.

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 The addendum is created in a temporary collector, ^Addendum, and assigned to the object,
Addendum1.

Step 6: Create the Die Cavity

1. Right-click on the white space in the Die Process tab and select Trim Binder > With
Addendum:

2. To see the cavity more clearly, rotate the model.

Step 7: Create the Punch and Binder

1. In the Die Process tab, right-click on Punch: (None) and select By Offsetting Part and
Addendum….

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 2. Enter a value for the offset. The offset distance will be the gap between the punch and the die,
which should be equal to blank thickness+20 percent of blank thickness.
3. Click Offset- based on the direction of the vector.
4. Click Return.
The punch will be created in a collector named Punch. The object punch in the die process tree
reflects the name of the punch component.
5. Right-click on Blank Holder: (None) and select By Offsetting Binder….
6. Enter a value for the offset. The offset distance will be the gap between the punch and the die,
which should be equal to blank thickness+20 percent of blank thickness.
7. Click Offset- based on the direction of the vector.
8. Click return.
The Blankholder will be created in a collector named Blank holder. The object Blank holder in
the die process tree reflects the name of the Blank holder component.
It is advised to keep the blank ready by using tools in the Part Feasibility module prior to creating
tools. You can also switch to the Incremental_RADIOSS user profile and use the functions Auto
Process and/or User Process to setup the solver parameters for RADIOSS Incremental.

Punch and binder with the die

9. to keep all of the elements/surfaces in one component, in the white space of the Die Process
browser, right-click and select Organize die.

This tutorial is now complete.

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HF-2010: Basic Addendum Creation with the Die Process

The Die Process utility provides a browser-based method for creating and editing addendum and the die
cavity.
The addendum is a part of the die face that facilitates the smooth and controlled flow of the metal into
the die cavity. HyperForm lets you create the addendum and construct a complete die with the part
profile as the input. After constructing the binder, you build the addendum, connecting it with the part
and the binder surface. Next you trim the binder to get a complete die cavity. You can also create the
addendum with different cross sections depending on the complexity of the part shape. You also have
the flexibility of modifying the cross section of the addendum depending on the changes to the part
design.
This tutorial assumes that you are familiar with basic HyperMesh functions such as creating components,
geometry cleanup, and meshing. Information on these topics can be found in the online help.

Step 1: Load the File

1. From the File menu, click Open....

2. Browse to the file <installation_directory>\tutorials\mfs\hf\die\cup_addendum.hf.
3. Click Open.

Step 2: Define the Die Process Settings

1. On the Die Process tab, under Settings, right-click Symmetry > Edit. The Symmetry Setting
panel appears.

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2. In the panel, set the Symmetry toggle to full (default).
3. Click return.
4. From the toolbar, select Preferences > HyperForm Settings.
5. In the dialog that appears, select the ProcessDefaults tab.
6. For BinderDepth, enter 10.0.
7. For BinderOffset, enter 50.0.
8. Click Apply, then Close.

Step 3: Prepare the Part for the Die Creation

1. On the Die Process tab, in the tree under Dies > Die1, right-click Part: (none) and select Set....
2. Select the part from the graphics screen and click proceed.
Note that the name of the component appears in front of the label Part:. For this example, Part:
Die1 appears. A copy of the selected part is made in component Die1 to create the die surface.
Also the outer boundary of the part is automatically determined and assigned as the trim line.

Step 4: Create the Binder

1. On Die Process tab, in the tree under Dies > Die1, right-click Addendum Start Line, and then
select Auto.
The addendum start line is automatically added to the component ^Die1_ASL1 and assigned to
the object Addendum start line.
2. Under Dies > Die1, right-click Binder, and then select Create. A new object, Binder1, is created
and the ASL created in the previous step is assigned to it.
3. Right-click Binder1, and then select Create > From Part:

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 The binder surface is created in the component Die1_Binder1 and assigned to Binder1.

Step 5: Create the Addendum

1. On the tree of the Die Process browser, under Die1, right-click Addendum, and then select New.
A new object Addendum1 is created and the binder created in the previous step is assigned to it.
2. Right-click Addendum1, and then select Create > From Part.

The addendum is created in a temporary collector, ^Addendum, and assigned to the object,
Addendum1.

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Step 6: Create the Die Cavity

1. Right-click on the white space in the Die Process tab and select Trim Binder > With
Addendum:

2. To see the cavity more clearly, rotate the model.

Step 7: Create the Punch and Binder

1. In the Die Process tab, right-click on Punch: (None) and select By Offsetting Part and
Addendum….
2. Enter a value for the offset. The offset distance will be the gap between the punch and the die,
which should be equal to blank thickness+20 percent of blank thickness.

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3. Click Offset- based on the direction of the vector.
4. Click Return.
The punch will be created in a collector named Punch. The object punch in the die process tree
reflects the name of the punch component.
5. Right-click on Blank Holder: (None) and select By Offsetting Binder….
6. Enter a value for the offset. The offset distance will be the gap between the punch and the die,
which should be equal to blank thickness+20 percent of blank thickness.
7. Click Offset- based on the direction of the vector.
8. Click return.
The Blankholder is created in a collector named Blank holder. The object Blank holder in the die
process tree reflects the name of the Blank holder component.
It is advised to keep the blank ready by using tools in the Part Feasibility module prior to creating
tools. You can also switch to the Incremental_RADIOSS user profile and use the functions Auto
Process and/or User Process to setup the solver parameters for RADIOSS Incremental.

Punch and binder with the die

9. To organize all of the elements/surfaces into one component, in the white space of the Die Process
browser, right-click and select Organize die.

This tutorial is now complete.

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HF-2020: Creating a Parametric Addendum

The addendum is a part of the die face that facilitates the smooth and controlled flow of the sheet metal
into the die cavity. HyperForm enables you to rapidly create a parametric addendum and construct a
complete die with the part profile as the input. First a developable binder is constructed and then the
addendum is built connecting the part and the binder surface. The binder is finally trimmed to get a
complete die face. An addendum can be created with single or multiple cross-sections depending on the
complexity of the part shape. You also have the flexibility of parametrically modifying the cross-sections
of the addendum in order to create different die geometries.
Three exercises are contained in this tutorial:
Exercise 1: Geometry cleanup for creating an addendum
Exercise 2: Building a flat binder and addendum with the Rib Editor

Exercise 1: Geometry

Step 2: Part Assignment

1. From the tree in the Die browser, right-click Part, and then select Set.
2. On the model graphics, left-click to select the part. To accept the selection, middle-click.
Note that the name of the component appears in front of the label Part. For this example, Part:
Die1 appears. A copy of the selected part is made in component Die1 to create the die surface.
Also the outer boundary of the part is automatically determined and assigned as a trim line.

3. ------------
4. Repeat Step 1 to turn on the Visualization toolbar.
5. From the Visualization toolbar, select Geometry Color Mode and change to By Topo.
Notice the color of the model is changed and topology definitions are displayed on screen.
6. Click the V key and click restore1 to retrieve the saved Notch1 view.
7. In the Utility Menu, click Edit Geometry.
8. Click the Spline button.

9. Click the entity selector switch on the left and select lines.
10.Click the switch in the middle of the panel and select surface only.
11.Verify that keep tangency is active.
12.Click on the red line as shown in the figure below and click create to make it green. This will build
a surface covering the notch.

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13.Click the V key and click restore2 to retrieve the saved Notch2 view.
14.You are still in the Spline panel. Click on the red lines, as shown below to fill the surfaces.

15.Click the V key and click restore3 to retrieve the saved Fillet corner1 view.
16.Click on the red lines, as shown below to fill the surfaces:

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17.Click the V key and click restore4 to retrieve the saved Fillet corner2 view.
18.From the Utility Menu under Create Surfaces, click on the Sweep button.
19.In the drag geoms subpanel, click the toggle next to drag: and set it to line list. In the same
row, set the toggle to use default vector.
20.Click the toggle to set the option surface only.
21.Click the drag: line list button and click the red line, as shown in the figure below.
22.Click the along: line list button and click the red line, as shown in the figure below.
23.Click drag.

24.Repeat the above two steps to close the other surface, as shown below.
The next two steps are optional and can be skipped if you see all green-shared edges without any
red edges.
25.(Optional) Click keyboard F11 to jump to the Quick Edit panel.
26.(Optional) Click the Line panel right next to toggle edge:. With the Line panel lines active,
graphically click the any interior red lines (free edges) within the circle regions in the image below.

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 This changes the selected red free edges into green shared edges.

27.From the Utility Menu, click on the <<<Back button. This will take you to the die concept
module menu.
28.From the File menu, click Save and save the file as Die_module_ex1_complete.hf.

This exercise uses the model files die_module_ex1.hf.

Step 1: Load the Model

1. From the File menu, click on Open.

2. Browse to the file <installation_directory>\tutorials\mfs\hf\die\Die_module_ex1.hf.
3. Click Open.

Step 2: Part Assignment

1. From the tree in the Die browser, right-click Part, and then select Set.
2. On the model graphics, left-click to select the part. To accept the selection, middle-click.
Note that the name of the component appears in front of the label Part. For this example, Part:
Die1 appears. A copy of the selected part is made in component Die1 to create the die surface.
Also the outer boundary of the part is automatically determined and assigned as a trim line.

Exercise 2: Building an addendum for a flat binder

This exercise uses the Die_module_ex1_complete.hf model from Exercise 1.

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Trim line (TL) is the entire outer boundary of the part. In HyperForm, you can use the Create Trim
line function to extract trim line from surfaces or meshes.
Step 1: Create a trim line for the part

1. From the Geometry menu, click Line Design. Select the part boundary subpanel.
2. Click surfs >> displayed.
3. Click create.
Notice all the shared green edges are turned into blue suppressed edges.
4. Click return.

Step 2: Create a flat binder

1. From the Geometry menu, click Binder, and select the flat subpanel.
2. Set the Offset value to 200.0 and toggle to full model.

3. From the tool bar, click the rear view icon.

4. With the yellow nodes button highlighted, click anywhere below the bottom of the model to
create a temp node.
When one node is created, HyperForm generates a plane surface perpendicular and horizontal to
the screen. If two nodes are selected, a plane is created based on the two nodes, that is,
perpendicular to the screen, passing through these nodes.

Single node selected on screen for creation of flat binder surface

5. Click create.

Step 3: Edit the flat binder

1. From the tool bar, click the top view icon. Notice that the original part is approximately
centered on the binder surface.

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2. Choose the rear view icon to change back to rear view.
3. You should still be in the Binder panel. Click the purple edit button.
4. Select the Translate subpanel.
5. Click on the switch next to N1, N2, N3 and make the direction as z-axis.
6. Press keyboard F4 to enter the Distance panel.
7. With N1 highlighted, hold the left mouse button and move the cursor on top of the edge of the
part to highlight it, and then click on the edge again to create a temp node N1. Refer to image
below.
8. With N2 highlighted, repeat the above step and create the temp node N2 on the binder. Refer to
the figure below. To make it easier to create N1 and N2, try changing the display to shaded
graphics.

Select nodes using the Distance panel

9. Note the value of z dist. Remember this value.

10.Click on return.
11.This should take you back to the Edit Binder panel. With the noted value from the distance
panel, use the expression (Distance to translate = | Z distance measured | - 80.0) to arrive
at a value so that the distance is equal to 80mm between the binder surface and the bottom
face of the part.
12.Enter that value in the Magnitude= field.
13.Click on Translate+ or Translate+ accordingly.
The end resultant distance between the part and the binder should be 80.0.

Picture showing the Binder and the Part

14.Click return.

Step 4: Build the addendum

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1. In the Model Browser, expand the Component folder to view the components. Right-click on
addendum and select Make Current. This changes the default working component to be
addendum.

2. From the Geometry menu, click Addendum, and select the Constant S-section subpanel.

3. From the toolbar, click the top view icon.

4. Click on the line button next to TL:. With the line button highlighted, pick the trim line from
the graphics screen. (Trim line is the red outer boundary of the part.)
5. Click on the surf button next to Binder:. With the surf button highlighted, click on the binder
surface from the graphics screen.
6. Click on the purple parameters button. This will take you to the control values for addendum
creation.
Note that the parameters for the constant S-section can be changed using the panel. The
available parameters for controlling the geometry generated include plus length, wall angle and

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 entry radius. Other surface generation options include:
Plus length: A straight line section added to the outer edge of a part (10 mm default)
Wall angle: Section wall angle (15 degrees default)
Entry radius: Die entry radius (10 mm default)
Constrain plus to part: Plus length will be constrained so that it is tangent with respect to the
edge of the part (ON by default)
Enable fixed points: Fixed points will be placed along the edge of the new addendum surface
if a finite element mesh exists. If the nodes lie along the edge and are within a tolerance, a
fixed point will be generated (ON by default)
Split into small faces: Generated surfaces are divided into smaller areas in order to simplify
their definition while reading and manipulating them in other CAD systems (ON by default)
Automatically add rib at sharp corner: HyperForm automatically puts a rib at those corners if
this option is turned on where the TL has a sharp transition (such as a corner) but without any
rib.
7. Enter Plus Length = 10.0, Wall Angle = 10.0 and Entry Radius = 10.0.
8. Click on return.
9. Click on create addendum.
This will create an addendum forming a smooth connection between the part and the binder
surface.
10.Click return.

Exercise 3: Building an addendum for a curved binder using the Rib Editor

The Rib Editor is a two-dimensional tool for use in the design of parametric cross-sections of an
addendum (referred to as ribs). A rib can be constructed from one or multiple basic shapes, referred
to as segments. After designing a rib, you can add it to the model, and an addendum shape surface
can later be constructed using all of the ribs created.
This exercise uses the model file die_module_ex3.hf.

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Step 1: Load the setup file

1. From the File menu, click on Open.

2. Browse for the file die_module_ex3.hf.
3. Click Open.

Step 2: Create a trim line for the part

1. Verify you are in the Die Module user profile.

2. From the toolbar, click Geometry Color Mode and change it to By Topo.
3. From the Geometry menu, click Line Design.
4. Click the surfs button and select displayed from the pop-up menu.
Notice all the shared green edges are turned into blue suppressed edges.
5. Click return.

Step 3: Display a side view of the part and set the current component

1. From the toolbar, select the rear view icon .

2. Press the keyboard - ( minus sign ) to zoom out. (You can also right-click from the tool
bar.)
3. From the Model Browser, right-click on the Binder component and select Make Current. This
changes the default working component to Binder.

Step 4: Create a singly-curved binder surface

1. From the Geometry menu, click Binder, and select the single curve subpanel. Ensure that the
toggle switch is set to full model.
2. Click nodes and select several points below the part in the viewing graphics area as shown in
the figure below.
If multiple nodes are selected, HyperForm generates a singly-curved surface which passes
smoothly through the nodes and is perpendicular and horizontal to the screen.

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3. Click offset = and enter 200.0.
The binder surface will be offset by the amount specified.
4. Click create.

Step 5: Edit the curved binder surface

There are several options available on the Binder panel that enables you to modify the shape of the
binder domain. You can also edit the geometry of a binder that has already been previously created.
1. Click the keyboard button. This rotates the model by 15 degrees.
2. Click the edit button to enter the Edit Binder panel.
3. Go to the create section subpanel. With the nodes button activated, hold the left mouse
button and move the mouse cursor to a location along the binder surface edge at far most
negative Y direction. Once the line is highlighted, click again to create a temp node. Refer to the
image below:

4. Click on the selector below Identify Section: and select the by nodes option.
5. Click and hold the left mouse button and move the mouse cursor to a location along the binder
surface edge at far most negative Y direction. Once the line is highlighted, click again to create a
temp node.
6. Repeat the same on the opposite edge and click Create.

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7. Repeat steps 3 through 6 and add 3 more track lines evenly distributed over the binder surface.
Notice several handles (represented by temp nodes) are created on the track line automatically.
8. Select the edit section subpanel.
9. Click line and pick the newly created line.

10.Graphically pick a node and drag it higher or lower. Notice the associated track line is lifted with
respect to the new location.

11.Click the cast section subpanel.

12.For Model Section: Line, select the track line you just modified in the previous step.
13.For Candidate Sections: Lines, select all the rest of the track lines.
14.Click cast. Notice all the candidate line shapes are changed.
15.Click update.
Notice the binder surface curvature is modified.

16.Click return twice to go back to the main menu.

Step 6: Prepare to create the addendum surface

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1. From the Geometry menu, click Addendum, and select the single section subpanel.
2. Click on the line button next to TL: and pick the trim line from the graphics screen (the trim
line is the red outer boundary of the part).
3. Click on the surf button next to Binder: and click on the binder surface from the graphics
screen.
4. Click parameters.
5. Click the split into small face checkbox to de-select this option.
6. Click the global smoothing checkbox to de-select this option.
In this exercise, a better surface quality can be obtained when the split into small faces and
global smoothing options are turned OFF. This is especially true when using multiple sections
where the transitions from one rib section to another rib section are complex.
7. Click return.
You are still in the Addendum panel.

Step 7: Review the Rib Editor

The Rib Editor (shown below) is a two-dimensional interface for use in the design of parametric
cross-sections of an addendum (referred to as ribs). A rib can be constructed from one or multiple
basic shapes, referred to as segments. After designing a rib, you can add it to the HyperForm
Solista model, and an addendum surface can later be constructed using all of the ribs created.
1. Click rib editor.

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Rib editor graphical user interface.

There are seven main areas in the Rib Editor window:

Tabs There are four tabs to choose from.

The Options tab displays a list of options to display, constrain, or edit the
ribs. Under this tab you have the following options:
Plus value: A straight line section added to the edge of a part. (10 mm
default)
Last Wall angle: Section wall angle. (15 degrees default)
Die Entry radius: 10 mm default
When the plus value, last wall angle and Die Entry radius are enabled, you
activate the global values. Any appended rib segments will use the activated
values as default. For example, if you activate plus length value = 10.0, any
further added new plus line segment in Rib Editor will have straight segment
= 10.0 as default.
Constraint to part: Activate this option to constrain the rib so that it is
tangent with respect to the edge of the part.
Constrain to Binder: Activate this option to constrain the rib so that it
is tangent with respect to the edge of the Binder.
Enable Handles: Activate this option to create a center for the curved
portion of the ribs on the graphics screen. This allows you to change the
curvature value by holding the yellow center button with left-click.
Show Scales: Activate this option to mark the graphics screen with
scales.
Show neighboring ribs: This function displays neighboring ribs, if any
exists.
Show part profile: Activate this option to show the profile of the part
along with the rib being created.

The Model tab provides the total number, names, and parameters of the
segments that constitute the current rib.

The Library tab allows you to load a file containing pre-existing shapes. You
can then retrieve the different shapes from the loaded library to construct a
rib. New shapes can also be added to the library file.

The Help tab shows the description of the Rib Editor.

Plot area Graphics display area for the ribs

Action buttons There are five action buttons.

Append: Adds a rib at the end of an existing rib.

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 Insert: Adds a rib at the start of an existing rib.
Replace: Replaces an existing rib with a new rib.
Delete: Deletes a rib.
Undo: Enables undo operation to the previous action.
Note: The current action mode is displayed on the toolbar directly above the
action buttons.

Toolbar The toolbar is composed of icons representing four basic shapes that can be
used to construct a rib (in addition to the library shapes):

Plus: Straight segment with length and angle

Fillet: Fillet with radius and span
Half-S-Shape: Straight segment with a fillet at the end
S-Shape: Composite shape consisting of 3 straight segments and 2
fillets
B-shape: Composite of two s-shapes (also called the draw bar)
Note: The parameters for the toolbar shapes can be changed in the
parameter display area (described below) or through the dragging and
dropping of control points from the options page.

Parameter Located in the area between the tool and status bars, the parameters of
display area shapes can be viewed and modified here.

Status bar Located at the bottom of the Rib Editor window, the status bar displays
messages concerning geometric constraints used during rib construction.

Viewing Several viewing options are offered in the lower right-hand corner of the
options window; such as zoom in, zoom out, and fit.

2. Verify that only Constrain to part and Show part profile are activated.
If show part profile is off, click the Options tab and select the ON check box next to the
Show part profile option. This will show a part profile in the display area as a red dotted
section line.

3. Right-click the zoom-out button twice on the viewing options bar.

4. While pressing the Ctrl key, use the left mouse button and draw a circle in the plot area to
zoom into the area shown in the following figure.

Note: You can also do it by clicking on Circle Zoom function from viewing options.

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 The part profile (red), part edge tangency (orange arrow) and the binder profile (light blue) are
shown in the image above.
5. Click Append . Notice status "action mode : Append" is displayed above action
buttons. This allows you to add any new shape to part edge tangency.

6. Click the Plus icon on the toolbar to append a plus section to end of part.

Note: A straight-line section tangent to the edge of the part is added as shown in the figure
below. Notice the two parameters Length and Angle are defined in the parameter display
area.

Also, notice the current action mode: is still set to Append. The append mode ensures that
any new rib created will be added to the end of the currently highlighted section. You can also
change the action mode: to Insert, Replace or Delete. You will continue this exercise with
the action mode: set to Append.

Plus length added

7. From the parameter display area, change Length: from 10.0 to be 3.0.
Notice the length is reduced in Plot Area.

8. Click the Fillet icon on the tool bar to append a fillet section to the end of the plus section.
9. From the parameter display area, change Radius: from 10.0 to be 5.0.

10.Click the S-section icon on the toolbar to append an S-section to the end of the fillet
section.
11.From the parameter display area, change all parameters for the S-Section as in the image

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 below:

Note: Click on the icon, using the left mouse button and zoom into the area to have a larger
graphical view.
12.Check the Constrain to binder option.
Notice the S-section is extended and attached to the binder profile. The parameters are also
adjusted. This ensures that the rib is tangential to the binder surface.

13.Click the Options tab and select the ON check box next to the Enable handles option. This
allows you to graphically change any of the rib sections.

Handles turned ON

14.Hold the left mouse button and move the mouse cursor on top of the handle.
15.Notice the handle is changed to red color. A message box is also displayed in Plot Area as
"First segment of S shape, length: 3.0, angle: 20.0".

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16.Keep holding the left mouse button and graphically drag the mouse cursor. In this step, it is
NOT required to exactly follow the parameters below.
Notice the first segment is extended and also parameters are updated accordingly.

17.Once the rib is defined, close the Rib Editor window. HyperForm Solista remembers the
shape of the rib and will apply it when you create the addendum.
18.From the tool bar, click comp: and select the addendum component. This allows HyperForm
Solista to set the addendum component to be the working component.
19.Click create ribs. Notice ribs are generated.

20.Click create addendum to create the addendum surface.

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HF-2030: Modifying a Parametric Addendum

The Modify Addendum panel allows you to parametrically modify the addendum geometry created in
the Addendum panel. Essentially, it provides you with highly efficient tools to change the rib
parameters by either dragging at the rib ends or modifying the geometry or location of the binder.
Modifying a portion of a rib ensures that the whole rib definition is carried over to the new location. More
ribs can be added to the addendum to improve the quality of the generated addendum. This allows for
local refinement of addendum surfaces without having to reconstruct the addendum surface. After new
ribs are modified or added, the addendum surface can be updated by the Addendum panel/multiple
sections to the new definition automatically.
In this exercise, you will learn:
How to modify addendum
How to add more ribs to an existing addendum
How to absorb new modified ribs and update addendum surface

Exercise: Modifying the Addendum Cross Section for a Controlled Flow of Metal

This exercise uses the model file Modify_an_addendum.hf.

Tools

This tutorial uses the following panels:

Addendum panel
Modify Addendum panel

Step 1: Load the model file and select shaded mode

1. From the File menu, click Open....

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2. Browse for the file Modify_an_addendum.hf.
3. Click Open.

4. From the toolbar, click the Shaded Geometry and Surface Edges button for shaded mode.

Step 2: Modify the addendum by increasing the wall angle

1. Click V on the keyboard and click on the restore1 button to retrieve a saved view.

2. From the Geometry menu, click Modify Addendum. Select the edit binder subpanel, and click
on update.
This will create the latitude lines and update the model to the 12.0 version.
3. Select the drag rib end subpanel.
4. Select the ribs shown in the image below.

5. Verify the toggle is set to modify last wall angle to select the method to use for modification of
the addendum.

Note:

modify plus will extend the plus tangent to the part.

modify last wall angle will change the angle of the last draw
wall.

6. Click get handle to activate the handle (yellow circular ball) at the rib ends.
7. Click move handle.

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8. Hold your left mouse button and move the mouse cursor on top of one of the handles in the
graphics region. Keep holding the left mouse cursor and move the handle in the outbound
direction on the binder surface.
Refer to the image below:

9. Click update to pass the rib ends through the handles and modify the addendum surface to pass
through the modified rib sections.
Notice the outer shape of the addendum is modified accordingly. The Edit Addendum panel
allows a quick update over the shape of addendum by dragging the handles.
10.Click reject to get back to the original configuration.
11.Click clear handles to remove the existing handle.
This process can be repeated to modify the plus value.
12.Click return.

Step 3: Modify the addendum using the latitude feature

1. From the Geometry menu, click Addendum and click the single section subpanel.
2. With the TL: line button highlighted, select the trim line and the binder surface, as shown below:

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3. Click on edit latitude lines. You will be taken to a new panel as shown below where you can drag
the latitude lines interactively to change the cross section of the addendum. The red lines you see
below are latitude lines.

4. With the latitude lines highlighted, click on the red lines, as shown below:

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5. Click on the second Lines button against Fixed Ribs: and select the fixed ribs, as shown below:

6. Click on the get handle button. Notice the two handles on the Latitude Line, as shown below:

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7. Click on move handle. Click and drag one of the handles either in the z direction or in the XY
plane.
8. Click on update. Notice that the cross section of the addendum changes.

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Step 4: Modify the addendum by adding ribs

1. From the tool bar, select the user view icon . Click restore2 button to retrieve the saved view.
2. You should still be in the Modify Addendum panel. Select the add rib subpanel.
3. Click line button and elect the rib to be copied as indicated in the image below.
4. Click the nodes button, keep holding the left mouse button, and move mouse cursor over the
nodal location as indicated in the image below. Release the mouse button and click the left mouse
button again to create a temp node.

5. Click add.
This will copy the rib and also modify the addendum surface to pass through the new rib. The
figure below shows the addendum surface before and after adding the rib.

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Step 5: Review the addendum rib

1. Select the edit rib parms subpanel.

2. Click the Line panel and graphically select the rib, as shown in the image below.

3. Click rib editor.

4. Graphically click the green rib as shown in the image below until it becomes white in color.

Note: All the parameters are displayed and can be modified and updated.

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Step 6: Modified ribs and update addendum surface

1. In the Rib Editor, change the Radius 2: from 10.0 to 15.0. Notice the selected rib is also
graphically changed.
2. Close the Rib Editor.
3. Click update.
Notice the rib and the associated addendum surfaces are updated.
4. Click return.

Step 7: Absorb new modified ribs and re-create addendum surfaces using
multiple sections

During previous steps, some ribs are modified and some addendum surfaces are split. In this step,
you will remove the split addendum surfaces by re-creating the addendum surfaces using existing
ribs.
1. Press F2 on the keyboard to open the Delete panel.
2. Click the toggle and change the selector to surfs.
3. Click surfs and select by collector.
4. Select the addendum component and click select.
5. Click delete entity to delete all addendum surfaces.
6. Click return.
7. From the Utility Menu, under Create Addendum, click on Multiple.
8. Click the toggle next to POL: and set it to with POL.
9. Click parameters and disable both split into small surface and global smoothing.
10.Click return to go back to the multiple sections subpanel.
11.Select the Binder surface, TL and POL line as shown in the image below.

12.Click create addendum.

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Notice that new addendum surfaces are created.

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HF-2040: Parameterization of External Binder and Addendum Section Using
Section Editor

In this tutorial, you will learn how to parameterize binders and ribs using the Section Editor in
HyperForm.
The Section Editor provides an easy method of parameterizing binders and ribs (addendum cross-
sections) that were created in a system outside HyperForm, such as Catia or AutoForm. You can modify
the geometry of the cross-sections, or integrate them to create a parametric addendum that can be
generated by HyperForm.

Exercise: Using the Section Editor

This exercise uses the model file section_editor_part.hf and geometry files external_binder.iges
and external_section.iges.

Tools

This tutorial uses the Section Editor, which can be accessed by:
the Section Edit panel
the Edit Section macro

Step 1: Open the model file

1. From the File menu, Open….

2. Browse to the section_editor_part.hf file.
3. Click OK.

Step 2: Import the binder data

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This model has a binder associated with it that is in IGES format. Your goal is to raise the binder
locally to create a curvature, thereby reducing the draw depth in the raised area of the part.

1. Click the Import icon and select the Import Geometry icon .

2. Click the Select files... icon and browse to the external_binder.iges file.
3. Click Import. The geometry appears below the part in the graphics area, as shown below.

4. Click Close to close the Import tab.

Step 3: Mesh the binder

To make future updates to the binder easier, it is recommended that you mesh the binder.
1. In the Model Browser, expand the Component folder.
2. Right-click on lv3 and select Rename. Enter the new name as Binder. Right-click on it again and
select Make Current.
3. From the Mesh menu, click R-Mesh to open the Rigid Tool Surface Meshing panel.
4. Accept the default values.
5. Click Mesh…
6. Select the binder surface in the graphics area and click proceed. HyperForm creates mesh on the
binder surface.
7. Click Close.

Step 4: Create the cutting plane

1. From the toolbar menu, click User Views and select top.
2. From the main menu, click section edit.
3. Click elems and select displayed from the extended entity selection menu.
4. Using the N1, N2, N3 and B selectors, select three nodes and a base node to define the cutting
plane, which corresponds to the raised area of the part. Refer to the image below.

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5. Click create section.

Step 5: Use the Section Editor to modify the binder

1. Click edit section.

The Section Editor opens in its own window. This editor displays a parameterization of the cut
you made in step 4. The parameterization is composed of multiple lines, which are listed in the
Model Browser. Specialized options are available in the Section Editor to manipulate the cross-
section.
2. With the Joints option selected, right-click the joints that are not endpoints to convert them to
points. (Joints are red solid circles and points are blue hollow circles.) Removing the joints causes
the section to become a straight line.

3. In the Radius subpanel, click and drag the section to the appropriate location to specify the peak
of the desired curvature of the section.

4. When you are satisfied with the curvature of the section, close the Section Editor and return to
the main panel of HyperForm. The modified section is shown in blue in the graphics area. (The
original location is shown in green.)

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 Note: The green line is the original cross-section. The new target cross-section line is the blue
line.
5. Click return to go back to the main menu.

Step 6: Morph the binder to pass through the modified cross-section

1. From the Applications menu, select HyperMorph.

2. From the main menu, click map to geom.
3. Set the left-most toggle to line difference.
4. For from line: select the original, green line. For to line: select the modified, blue line. These
selections indicate that the original line will be morphed to the location of the blue line.
5. In the same panel, switch map domains to map nodes.
6. Click nodes and select by collector.
7. Select binder to select all the nodes in the collector that correspond to the binder.
8. Click map. The mesh is mapped.
9. Click return.
Next you must map the surface.
10.From the main menu, select Morph.
11.Select the morph surfaces subpanel and click morph surfs. The binder surface has now been
updated to pass through the parametric cross-section.
12.Click return twice to close the panels.

Step 7: Import the geometry file containing ribs

1. Click the Import icon and select the Import Geometry icon .

2. Click the Select files... icon and browse to the file external_section.iges.
3. Click Import to import the file.

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 Notice an addendum rib is imported.

Step 8: Create a collector to contain the new surfaces

1. Right-click anywhere in the white space in the Model Browser and select Create and then select
Components, as shown below.

2. Type the name as addendum and choose a color.

3. Click create.

Step 9: View and export the rib

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1. From the Utility Menu, click on the Edit Section button.
2. Set the entity selection menu to lines.
3. In the graphics area, select the rib and click edit section.
4. The Section Editor opens. Note that the rib is already parameterized and is composed of arcs and
lines, as listed in the Model tab.

5. On the Export tab, enter save1 in the Current section: field and click Save.
The rib section appears in the list.
6. Close the Section Editor and click return to close the Edit Section panel.

Step 10: Create the parametric addendum

1. From the Geometry menu, click Addendum and select the single section subpanel.
2. Select the outer edge of the part for the trim line (TL field) and the outer edge of the binder for
the Binder field.
3. Click rib editor. The Rib Editor opens in its own window.
4. Click the Library tab and note that the save1 rib appears in the list.
5. Click the rib name in the list and note that a preview of the rib appears in the left side of the Rib
Editor window, where you can see the geometry, including the parameters you created.

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6. Click the Append button to change the action mode, and then click the library button to append
the rib to the part’s geometry. Note that the rib extends beyond the binder surface.

7. In the graphics area, double-click the last segment of the rib to select and highlight it. The
segment beginning beyond the binder boundary will be deleted.

8. Click delete to delete the segment.

In steps 9 through 12, you will modify the last section’s length and angle so that the rib does not
cross the binder. Then you will constrain the rib to the binder.
9. In the graphics area, click the last segment, as shown in the image below.

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 10.For Length:, change the value from 24.2 to 10.0 and press ENTER.
Notice the last segment is no longer passing the binder’s boundary.
11.Click the Options tab.
12.Check the Constraint to binder checkbox.
13.Notice the rib is adjusted so that it can attach to the binder.

14.Close the Rib Editor, which will return you to the Addendum panel.
15.Click create ribs. HyperForm automatically creates ribs based on the parameters you have set.
16.Click create addendum. HyperForm creates the addendum.

Step 11: (optional) Save the model as section_editor_part_complete.hf

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RADIOSS Incremental Tutorials

HF-3000: Auto Process

HF-3010: User Process
HF-3020: Setting Up a Multistage Simulation with the User Process
HF-3030: Post Processing Forming Results in HyperView
HF-3040: Redraw Forming Analysis from the User Process
HF-3050: Gravity
HF-3060: Trimming
HF-3070: Springback
HF-3080: Hot Stamping
HF-3090: Setting Up a Composite Forming Simulation
HF-3100: Post Processing Composite Forming Results in HyperView
HF-3110: HydroForming
HF-3120: Tube Bending
HF-3130: Blank Shape Predictor

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HF-3000: Introduction to Incremental_RADIOSS and Incremental_LS-Dyna

In this tutorial, you will learn the fundamentals of Incremental_RADIOSS and Incremental_LS-DYNA
using HyperForm.

Tools

The table below lists the tools used in Incremental_RADIOSS and Incremental_LS-DYNA analysis:

Tool Function

Sections panel Creates section properties for a component and define

the corresponding thickness.

Materials panel Creates the material properties for a rigid tool or a

deformable blank.

Creates a hardening curve corresponding to the stress-

strain behavior of the deformable blank based on a power
law or as a set of points from an external file.

Components Creates a component and prescribe the corresponding

panel elements, section and material properties. A toggle
switch enables adaptive meshing for a deforming blank if
required.

Loadcols panel Creates a load collector that may hold applied velocities,
forces, or constraint conditions.

Curves panel Creates a curve by inputting the data in the available

fields or by reading an external file.

Reviews or modifies any curve inside the current model

using the internal function.

Tool Build panel Several tool creation and positioning options: The auto
build/setup function automatically creates additional
tools by offsetting, creates material definitions, creates
contact definitions and auto positions the tools. The tool
offset function creates a new mesh component by
offsetting elements of another. The auto position function
positions two or more components until they are just in
contact.

Tool Motion Allows you to prescribe the motion of the tools. It

panel automatically calculates the velocity curve and
termination time for a moving tool based on its expected
travel and maximum velocity. The history function
automatically calculates a time step for a stable and
accurate solution and also allows you to prescribe the

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 intervals at which the results are output.

Tool Loads Allows you to prescribe a force to a specified rigid tool. In

panel Incremental_LS-DYNA, it allows you to choose rigid body
stoppers to limit the displacement and velocity in order
to minimize the inertial effects for the rigid tool under a
specified force.

Drawbeads Allows you to set up analytical drawbeads that create

panel restraining condition during stamping. The inputs for the
drawbead forces can either be numbers corresponding to
the restraining and closure force or you can just prescribe
it as a percent of the locking force.

The calculate function computes analytically, the

restraining, closure and locking force as well as the
geometry that causes locking based on a prescribed
drawbead geometry, material properties and friction
conditions for the deforming blank.

Contacts panel Allows you to set up contact condition between a single

pair of components or multiple sets of components.

Penetration Allows you to check components for contact surface

panel penetrations. It also allows you to determine how much
penetration is occurring and move the penetrating nodes
in order to eliminate the penetration.

Advanced panel Allows you to set up advanced forming processes.

Trimming and springback can be setup in the
Incremental_RADIOSS user profile. Gravity, springback,
trimming, coarsening, and mapping can be setup in
Incremental_LS-DYNA profile.

Run Analysis Allows you to automatically create the input file and
panel interactively submit the job for a RADIOSS/LS-DYNA
analysis. A summary sheet can be invoked which will
show a brief overview of the input data. A preview
animation of the tool motion is possible from this panel.
An option to write out a sta/dynain file with the mesh
and adaptivity data as well as thickness, stresses and
plastic strain can be toggled from this panel.

Load Result Allows you to automatically invoke HyperView for

panel visualizing the results corresponding to the current
model. HyperView is a high performance visualization
tool with a multitude of features to help review metal
forming analysis results.

Auto Process Macros for automation of stamping process setup. All the
Incremental_RADIOSS and Incremental_LS-DYNA

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 forming processes can be easily set up and reviewed.

Multi-stage Macros for automation of multi-stage forming process set

Manager up.

HyperMorph The HyperMorph module allows users to alter models in

useful, logical, and intuitive ways while keeping mesh
distortion to a minimum. Any morphed operation can be
saved as shape entities for performing shape
optimizations afterwards.

HyperStudy An integrated optimization, DOE, and robustness engine.

All forming analysis result can directly transferred to
HyperStudy. Hyperstudy in the Incremental_RADIOSS
user profile can be accessed from Applications menu.

Process Manager Pre-defined standard work processes. It enables you to

rapidly develop and deploy process automation
applications for standard product engineering practices
within the HyperWorks environment.

Section 1: Introduction to Incremental_RADIOSS and Incremental_LS-DYNA

Forming Analysis

This section introduces the HyperForm Incremental Interface for setting up an incremental
metalforming analysis using RADIOSS / LS-DYNA.
The HyperForm Incremental_RADIOSS user profile provides a customized interface to set up an
incremental metal forming analysis using RADIOSS, and the Incremental_LS-DYNA profile provides a
customized interface to set up an incremental metal forming analysis using LS-DYNA.
You can accurately model forming processes. Instead of modeling just the final part shape, as in One-
Step metal forming analysis, this uses a more rigorous modeling approach. As the name implies,
small solution steps or increments are taken to solve the problem. In this way, the incremental
method allows you to accurately model important metal forming processes (for example: binderwrap,
single or multi-stage forming, trimming, and springback). Solving a problem incrementally allows you
to detect the stage at which the process defects (for example: wrinkles, thinning or tears) occur in the
blank. You can then take corrective action to eliminate these defects by modifying the process in
various ways (for example: changing tool loads, tool motion, or tool shape). The Incremental method
allows you to represent all tool surfaces, prescribe the tool motions, apply tool loads, define material
properties of the blank, and model the contact interaction between the tools and the blank.

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Section 2: The interface

The Incremental_RADIOSS and Incremental_LS-DYNA user profiles support incremental metal

forming analysis using the RADIOSS and LS-DYNA solver. Panels help set up the following input
conditions for an incremental analysis in a highly automated fashion. You can define:
Input parameters, such as material properties for a deforming blank
The relative position and contact condition of the stamping tools
Process conditions such as tool kinematics, drawbeads, and blankholder tonnage
Automatic process for multi stage forming operations
Optimization
Result evaluation and mapping

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 Incremental_Radioss panel

Section 3: Process Macros

Application
All the incremental macros are located on the RADIOSS and Dyna page of the macro area (lower-
right-hand side of the HyperForm window). These macros allow you to more easily setup different
application types, such as:

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 Form – 1st forming operation setup
Multi – 2nd or nth forming operation setup
Trim – Trimming operation setup
Coarse – Coarsening of blank mesh setup
Sprbk – Springback setup
Grav – Gravity setup
Bend – Tube bending setup
Hydro – Hydro forming operation setup
Blank Optimizer – Generate a new blank shape based on the applied deviation represented by
a reference trim line
Model
Macro panels are used to load model, remove holes and mesh tool (R-Mesh) and blank (B-Mesh).
Setup
The setup process will change according to the application type chosen. The sequence of tasks starts
from the top and guides you through each step included in the specific application type. Further
explanation of each application type will be provided in later chapters.
Results
Allows users to generate a report in selected types and styles. Advance report can allow user to
interactively zoom in, animate, rotate and contour plot a model in Microsoft PowerPoint.

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HF-3000: Auto Process

This tutorial teaches you how to use the Auto Process utility to set up and run an incremental stamping
analysis with RADIOSS or LS-DYNA.

Prerequisites
Familiarity with basic HyperMesh functionality such as geometry cleanup, meshing, and mesh editing.
To learn more about these functions, see the HyperMesh tutorials in the online help.

Overview of Auto Process

You can access Auto Process from the Tools menu in the Incremental_RADIOSS or
Incremental_LS-DYNA user profile.
Note:
You can choose to set up a simulation from either user profile, however you should not switch
between the two in the middle of the setup.
To setup an analysis for LS-DYNA, select the LS-DYNA user profile, and then apply the same
methodology for the RADIOSS user profile as shown in this tutorial.

The Auto Process option leads you through two major steps: Setup and Detail:

Step Description

Setup This step lets you select an analysis type, and specify the essential input
parameters for your simulation. The blank and tools of the forming process
have fields for you to enter values. After entering the values, you can select
Auto Position to automatically adjust the position of the tools.
The Apply option lets you save the current tool and blank settings, generate
load curves and create the input files for the RADIOSS solver. Afterwards,
you can verify that the tool motion is correctly defined by reviewing
animation control.

Detail This step lets you review the setup and make modifications to the input data
as necessary.

Exercise 1: Set Up the Model for an Incremental Analysis

This exercise is based on the model file, forming_autoprocess.hf.

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Step 1: Load the file

1. From the File menu, click Open.

2. Browse to the file <installation_directory>\tutorials\mfs\hf\incremental
\forming_autoprocess.hf.
3. Click Open.

Step 2: Open and review the Auto Process

1. On the toolbar above the modeling window, click the Single Action Draw icon.
2. On the error message that displays, click OK.
The Autoprocess panel opens:

Note:

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 Components are recognized if the names are identical or have common letters to the tool
nomenclature in the Auto Process macro such as Blank, Die, Punch and Binder.
The colors of the components are picked up by the schematic of Single Action Draw inside
of Auto Process.
Parts that are not recognized appear with dashed lines within the Auto Process image.

Step 3: Position the die, punch, binder, and blank

1. Check that the Process field is set to Single Action Draw.

2. For Draw beads, select No.
3. For Symmetry/Constraints, select –x (Symmetric to YZ plane).
4. For Draw direction, select –z.
Note: In a Single Action Draw, the die closes in by following the negative Z direction.
5. Verify that the file type is HF in the Source file column for Blank1, Die, Punch and Binder.
You have two options: HF and Geometry file. For Blank1 you have an additional option of
STATE file.

6. Use the pull down selector in the Component column and select the components sheet,
Top, Punch and Binder as you see in the following image:

Notice the components are recognized with a solid line in the Auto Process image.
7. Click the Autoposition button.
8. In the warning dialog that appears, click Proceed, and then do one of the following:
To apply the tool travel values calculated by the utility, click Apply.

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 To apply values that are user-defined, click Cancel, and then select a tool Name to activate
the column headings for that tool. Enter the appropriate values in the travel fields, and then
click Apply.

Step 4: Review blank parameters

1. Click the space next to the component Blank1. The arrow activates the component and lets
you modify parameters for that component.

2. Define the material and thickness for the blank:

For Material, select CRDQ steel (default).
For Thickness, enter 1.0 (blank thickness in mm).
Define the other fields as you see in the image above.
3. Click the Autoposition button.
Travel distances are calculated and the respective boxes are populated accordingly.
All tools move to the appropriate location so that they just touch the blank as you see in
the following image:

Note: In order to use your own values for tool travel and velocity, simply edit the values in the
respective boxes, and then click Apply. Do not click Autoposition.

Step 5: Review die parameters

1. Click the space next to Die. The arrow activates the component and enables you modify
parameters for that component.

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 Travel 1: The distance the die travels towards the binder (mm).
Velocity 1: The velocity at which the die travels towards the binder. The suggested velocity is
2000 mm/s.
Travel 2: The distance the die travels towards the punch (mm). Enter 70.0.
Velocity 2: The velocity at which the die travels towards the punch. The suggested velocity is
5000 mm/s.

Step 6: Review punch parameters

1. Click the space next to Punch. The arrow activates the component and lets you modify
parameters for that component.

Clearance: The distance between the punch and the blank at the initial configuration. Keep
default setting 0.0.

Step 7: Review binder parameters

1. Click the space next to Binder. The arrow activates the component and lets you modify
parameters for that component.

Type: The type can be either Force, or Gap:

Force: In this method, a force is applied to keep the binder closed.
Gap: Gap (mm) is defined as the actual physical distance between the binder and die that is

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 maintained after the binder closure until the draw is completed, after subtracting the blank
thickness.
2. Select the type as Force, and in the Force field, type 100000.

Step 8: Assign and review materials

1. Click the Blank1 field again. Under Material, click to open the material database:

2. In the steel folder, click CRDQ.

The material data is shown in RADIOSS keyword format along with a curve that corresponds to
the stress/strain data. Click Select to make the selection.
Notes:
You can maintain a custom material database. To do so, create the data in RADIOSS keyword
format and copy it to

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 <HyperWorks>\hm\scripts\hyperform\automation\materialdb\materials\steel.
To define a user material library for incremental runs, define the following cards:
/BEGIN, /UNIT, /MAT, /FUNCT and /END
3. (Optional) Use any text editor to open and review the CRDQ material data in the library.
<HyperWorks>\hm\scripts\hyperform\automation\materialdb\materials\steel\CRDQ.rad
#RADIOSS STARTER

##==================================================================

##

## Radioss Input Deck Generated by HyperMesh Version :

## Generated using HyperMesh-Radioss Template Version :

## Date: 01-30-2009 Time: 17:56:28

##

##==================================================================

/BEGIN

CRDQ.rad

51 0

##

##

/UNIT/MASS/1.0

/UNIT/LENGTH/1.0

/UNIT/TIME/1.0

##------------------------------------------------------------------

## Material Law No 43 HILL ORTHOTROPIC (Plasticity defined by a user function)

##------------------------------------------------------------------

/MAT/HILL_TAB/1

CRDQ

7.80000000000000E-09

210000.0 0.3

1.6 1.6 1.6 0.0

##------------------------------------------------------------------

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 ## Functions

##------------------------------------------------------------------

##HWCOLOR curves 1 11

/FUNCT/1

crdq_stress_strain

0.0 185.0

0.05 293.188135

0.1 339.127251

………………………………………………………
………………………………………………………

##------------------------------------------------------------------

## End Of Radioss Block Deck

##------------------------------------------------------------------

/END

4. Click Close to close the dialog.

Step 9: Model analytical drawbeads using the Drawbeads Editor

When Drawbeads is set to yes in the Auto Process, you can launch the Drawbeads Editor using
the button. The Drawbeads Editor helps you quickly create analytical
drawbeads from lines and rapidly manipulate them. You can also edit drawbeads by clicking in the
modeling area.
1. To create the Drawbeads row in the table, in the Auto Process panel, next to Drawbeads,
select Yes.

2. To launch the Drawbeads Editor tool, click .

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 The following tools are available on the Drawbeads Editor toolbar:

Button Function

In the drop-down menu, select Both to display both the drawbeads and
lines in the model representation, Drawbeads to display only the
drawbeads in the model representation, or Lines to display only the
lines in the model representation.

Create a drawbead by clicking points to define the line. When the points
are in place, right-click to set the line and create a corresponding
drawbead based on the line.

Click to add a drawbead to the table. Then complete the fields for the
row in the table to define the drawbead.

Click lines to select them. Lines appear as blue dashes. When they are
selected, they become yellow.

Click to add a drawbead for each line.

Click to delete the active drawbead from the table. The active drawbead
in the table has a gray arrow next to it.

Click to delete all drawbeads.

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 Click on a drawbead in the model to select it.

Click a drawbead to select it and then click and drag endpoints to

change the size of the drawbead.

Click a point on a drawbead to split the drawbead into two drawbeads at

that location.

Click two drawbeads when the button is selected to combine them into a
single drawbead.

Click the button to undo the last action in the Drawbeads Editor. You
can also right-click to sequentially remove the most recently created
points.

In the drop-down menu, select:

Force to set the force calculation mode as the default, which requires
that you supply values for restraining and closure forces. You can also
use the Drawbead Calculator to determine values.
or
%-lock to set the force calculation mode as percent lock, which applies
force as a percentage of the required necking force.

Click to fit the model to the current window size.

Zoom feature. Click once to fit the model in the window. Click and drag
to draw a rectangle to zoom in on that selection area.

Click and drag to move the viewing area when the model is zoomed in.

4. Click the pencil button .

5. Graphically draw a blue line on simplified graphical representation of the model in the top area
of the Drawbeads Editor, as shown below.

6. After selecting the points, click the create button to complete the first line. Notice the color

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 changes to yellow and the drawbead table displayed.

7. Repeat the same steps to create DB2 and DB3, as shown below.

8. Click the space left of DB1. Notice the corresponding drawbead line changes from green to
yellow in the graphics region.

9. Click after the Tstart column in the same row as DB1. This will open the Drawbead
Calculator as shown below.

10. Accept the current settings and click . Notice all the resultant conditions are calculated for
the given geometry, blank material, and thickness.

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 11.Click Back.
Notice that the calculated restraining force and normal force are automatically updated.
12.In the Drawbeads Editor, follow the same steps for DB2 and DB3 to input values for all
drawbeads.
13.Click Update to create the force curves for the drawbeads.
14.Click Back to return to the Auto Process setup page.
15.In the Auto Process panel, click Apply.
Note: In the Model Browser, expand the Component folder and locate three components:
^db_line for DB1, ^db_line for DB2 and ^db_line for DB3. These components are
generated automatically, and correspond to the three drawbeads.
Step 10: Review the animation control

The Animation Control field makes it possible to verify that the motion is set up correctly. Click
the arrow buttons to move forward or back through the process, and observe how the tools move
with respect to the blank in the graphics area.

1. From the Auto Process macro module, click in the animation control field to visualize the
tool positions at the termination of the forming stage. .

2. Click to get the model position back to initial configuration.

Exercise 2: Review in Input Data

Step 1: Review items on the Details tab

1. Click the Details tab.

2. Click the selector and change to All.

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 Note: You can select any option to review.
3. From the Select field, select Die.
You can review the attributes of the die by clicking each item in the tree.
4. In the die attribute tree, review the Velocity Curve as shown in the image below.
5. The curve is displayed on the right hand side and the values are editable. Click the Preview
button to preview the new curve after editing and then click on the Apply button to accept the
new curve.

This picture shows the velocity curve for the die.

6. From the Select field, select Summary.

7. Click Motion Summary.

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 8. Click Force Summary.

9. From the Select field, select Control.

10.Click each tree selection and review each topic.
11.Click Animation: Count from the tree selection.
12.Click the selector next to Animation.
Notice two types of result requests:
Count: Number of result types that are desired.
TFreq: which is displayed at different time intervals until the end of the simulation.

Exercise 3: Save the File and Run the Analysis

1. To start the analysis, from Auto Process, click Run.

2. When the Save as window appears, save the file name as forming_autoprocess_complete.
Note: This operation writes out a <filename>_0000.rad and <filename>_0001.rad file and
launches the RADIOSS solver.
3. From the File menu, click Save As, and save the file as forming_autoprocess_complete.hf.

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HF-3010: User Process

The User Process is a utility you can use for setting up a stamping process from scratch.
Benefits of the User Process include:
Setting up a unique forming process that you can save as a template, and then retrieve and
reapply with no input or minimal input for a successive setup.
Flexibility to include any number of tools.
Flexibility to change the orientation of the tools.
Tool kinematics that do not need to follow the conventional forming types, such as Single Action
Draw, Double Action Draw, etc.
Setup of a model in the Auto Process is captured in the User Process from the model definition.

Exercise 1: Set Up the Model for an Incremental Analysis

This exercise uses the model file forming_userprocess.hf.

Step 1: Load the File

1. From the toolbar, select File > Open.

2. Browse to the file: <installation_directory>\tutorials\mfs\hf\incremental
\forming_userprocess.hf, and then click Open.

Step 2: Define Process Parameters

In the User Process tab, adjust the settings as follows.

1. Right-click Symmetry, and then select –X.
2. Double-click Animation: Count, and then change the value to 15.
3. For Draw direction, keep the default setting: Z.
4. For Motion Mode, select Velocity.
5. For Memory Mode, keep the default setting: Automatic.
6. Right-click Adaptivity, and then select On.
7. Right-click Process Type, and then select Forming > Single Action.

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Step 3: Set Up the Blank Parameters

Complete the steps below to set up the blank parameters.

1. Right-click Blank > Component > Sheet.
2. Under Blanks, right-click Material, and then select Database…. The Material Database
dialog appears.
3. In the Steel folder, click CRDQ, and then click Select.
The material data is displayed in RADIOSS keyword format along with a curve that corresponds
to the stress/strain data.
Notes:

You can maintain a custom material database. To do so, create the data in RADIOSS keyword
format and copy it to
<HyperWorks>\hm\scripts\hyperform\automation\materialdb\materials\steel.

To define a user material library for incremental runs, define the following cards:

/BEGIN, /UNIT, /MAT, /FUNCT and /END

(Optional) Use any text editor to open and review CRDQ material data in the library.
<HyperWorks>\hm\scripts\hyperform\automation\materialdb\materials\steel\CRDQ.rad
#RADIOSS STARTER

##

## Radioss Input Deck Generated by HyperMesh Version : 8.0SR1

## Generated using HyperMesh-Radioss Template Version : 8.0sr1

## Date: 08-07-2007 Time: 17:56:28

##

##==================================================================

/BEGIN

CRDQ.rad

51 0

##

##

/UNIT/MASS/1.0

/UNIT/LENGTH/1.0

/UNIT/TIME/1.0

##------------------------------------------------------------------

## Material Law No 43 HILL ORTHOTROPIC (Plasticity defined by a user function)

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 ##------------------------------------------------------------------

/MAT/HILL_TAB/1

CRDQ

7.80000000000000E-09

210000.0 0.3

1.6 1.6 1.6 0.0

##------------------------------------------------------------------

## Functions

##------------------------------------------------------------------

##HWCOLOR curves 1 11

/FUNCT/1

crdq_stress_strain

0.0 185.0

0.05 293.188135

0.1 339.127251

………………………………………………………
………………………………………………………

##------------------------------------------------------------------

## End Of Radioss Block Deck

##------------------------------------------------------------------

/END

Note: An easy way to create your own material would be to substitute your data into an existing
material and save it under a new name.
4. In the User Process tab, double click Thickness: 1.0 and change the value to 1.5.

Step 4: Set Up the Tools Parameters

1. Right-click Die_sad > Component > Top.

2. Under Binder, click the field Force:-1000.0, and then click the value -1000.0 to make it
editable. Enter the value -10000.

Step 5: Model Analytical Drawbeads Using the Drawbead Editor

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1. From the User Process tab, right-click Drawbeads, and then select Edit Drawbeads....

Drawbeads Editor Toolbar

The following tools are available on the Drawbeads Editor toolbar.

Button Function

In the drop-down menu, select Both to display both the drawbeads and
lines in the model representation, Drawbeads to display only the
drawbeads in the model representation, or Lines to display only the lines
in the model representation.

Create a drawbead by clicking points to define the line. When the points
are in place, click Create to set the line and create a corresponding
drawbead based on the line.

Click to add a drawbead to the table. Then complete the fields for the row
in the table to define the drawbead.

Click lines to select them. Lines appear as blue dashes. When they are
selected, they become yellow.

Click to add a drawbead for each line.

Click to delete the active drawbead from the table. The active drawbead in
the table has a gray arrow next to it.

Click to delete all drawbeads.

Click on a drawbead in the model to select it.

Click a drawbead to select it and then click and drag endpoints to change
the size of the drawbead.

Click a point on a drawbead to split the drawbead into two drawbeads at

that location.

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 Click two when the button is selected to combine them into a single
drawbead.

Click the button to undo the last action in the Drawbeads Editor.

In the drop-down menu, select:

Force to set the force calculation mode as the default, which requires that
you supply values for restraining and closure forces. You can also use the
Drawbead Calculator to determine values.
or
%-lock to set the force calculation mode as percent lock, which applies
force as a percentage of the required necking force.

Click to fit the model to the current window size.

Zoom feature. Click once to fit the model in the window. Click and drag to
draw a rectangle to zoom in on that selection area.

Click and drag to move the viewing area when the model is zoomed in.

2. Click the pencil button .

3. Graphically draw a blue line on simplified graphical representation of the model in the top area
of the Drawbeads Editor, as shown below.

4. After selecting the points, click the create button to complete the first line. Notice the color is
changed to yellow and the drawbead table is displayed.

5. Repeat steps 2 - 4 to create DB2 and DB3, as shown below.

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6. Click on the space left of DB1 under the Name column. Notice that an arrow appears and the
corresponding drawbead line is changed from green to yellow in graphics region.

7. Click on the … button after the Tstart column in the same row as DB1. This opens the
Drawbead Calculator, as shown below.

8. Accept the current settings and click . Notice all the resultant conditions are calculated for the
given geometry, blank material, and thickness.

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9. Click Back.
Notice calculated restraining force and normal force are automatically filled in.
10.In the Drawbeads Editor, follow the same steps for DB2 and DB3 to input values for all
drawbeads.
11.Click the Update button to create the force curves for the drawbeads.
12.Click the Back button to return to close the Drawbeads Editor.

Note: In the Model Browser, expand the Components folder. You will find three
components: ^db_line for DB1, ^db_line for DB2 and ^db_line for DB3. These
components are generated automatically, and correspond to the three drawbeads.

Step 6: Prepare the Model to Run

1. Right-click anywhere inside the red boundary and select Autoposition as shown below:

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 The status of auto positioning is shown and updated at the left hand bottom corner of the
window. Done indicates that tools have been successfully positioned with respect to blank.
2. Right-click any where in the red boundary as shown in the above figure and select Run.
3. At the prompt to create input, click Yes.
4. Enter a filename, and click Save.
This will create a RADIOSS input deck which consists of two files:
<file name>_0000.rad and <file name>_0001.rad
5. Right-click anywhere in the red boundary as shown in the above figure and select Check
Model. This action checks the model for any errors and opens a box that includes the following:
A Sequence tab that displays the tool kinematics sequence
A Messages tab that displays errors in the setup, if any.
Preview animation of the tool kinematics.

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 6. Click the Binder motion curve block to highlight the border with thick black line.
7. To change the tool motion interactively, click and drag the thick black border.
8. Right-click Process, and then Save As Process:

9. Enter User_Process in the file browser, and then click Save.

Exercise 2: Retrieve the Saved Process to Setup a Second Model

This exercise will make use of the model Forming_ReUse_User_Process.hf.

Step 1: Load the HyperForm file

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1. Click on File and select Save As… to save the existing file in the session.

2. Click on the New .hm File icon . This deletes the existing model from the session. Note that
the parameters under the process tree is empty.

3. Click on Open Folder icon and browse for the file Forming_ReUse_User_Process.hf. Double-
click to open the file.
4. Right-click on Process and select Load Process… as shown below.

5. Browse for the file User_Process.up and double-click the file. A dialog box appears as shown
below. Click OK to bring the process file into HyperForm session.

Notice that the process tree gets populated as per the settings of the imported process file.
Step 2: Set up a second stamping model using the retrieved process file

The model and the retrieved process in the session look as below:

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1. Right-click on Symmetry and select No.
2. Right-click on the component name Sheet and select Component and select Part.
3. Right-click on the component named Top and select Component and select Die.
4. Right-click on the component named Die and select Component and select Binder.
5. Right-click on the component named Punch and select Component and select Punch.
6. Follow points 1 through 6 of step 5 from Exercise 1 to Autoposition, create input, export and run
the model.

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HF-3020: Setting Up a Multistage Simulation with the User Process

This tutorial teaches you how to set up a multistage simulation with the User Process utility.

Enabling Multistage and Setting the Root Directory

1. Launch HyperForm with the RADIOSS Incremental user profile.

2. From the User Process tab, right-click Process: Default Process, and then select Multistage >
Enable:

The Multistage tab appears with setup options for your simulation. The options on this tab are
similar to the ones on the User Process tab for a single-stage forming setup.

3. On the tree, right-click Base Directory > Set, and then in the dialog that appears specify the
directory where you want to save the results of the forming sequence.

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Set Up the Multistage Simulation

The multistage simulation for this tutorial uses the following forming sequence: Gravity, Double-
Action Draw and Trimming.

Stage 1: Gravity

1. On the Multistage tab, locate the forming template, and then double-click the Gravity tool: .

Gravity appears in the Process Sequence for your simulation:

2. On the tree, right-click , and then select Details from the context menu. The Stage 1 tab
opens and displays the gravity settings.
3. Select File > Open and load the file: <install_directory>/tutorials/mfs/hf/Incr/
multistage_gravity_radioss.hf.

The model on your screen should look something like this:

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4. From the tree in the User Process, check that the Blank and Die objects are pointing to their
respective components. If not, under Blanks, right-click Blank, and then select Blank >
Component. Do the same for the Die. Under Tools, right-click die, and then select component.
The default settings for Material and Thickness appear under the Blank. To learn about modifying
these settings, see HF-3010: User Process.
5. From the top of the tree in the User Process, right-click Process: multistage_gravity_radioss,
and then select Autoposition.
6. Right-click Process: multistage_gravity_radioss, and then select Create Input. The setup is
captured and reflected in the tree.

Stage 2: Double Action Draw

1. Click the Setup tab, and then double-click the Forming tool: .
The Forming tool appears below the Gravity tool and the Stage 2 tab appears:

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2. Right-click , and then select Details. The Stage 2 tab opens.
3. Select File > Open, and then navigate to the file: <install_directory>/tutorials/mfs/hf/
Incr/multistage_double_action_draw_radioss.hf.
The model on your screen should look something like this:

4. On the tree, under Process: multistage_double_action_draw_radioss, right-click Process

Type: > Forming > Double Action.
5. On the tree, under Tools, make sure that the die, binder and punch are pointing to the their
corresponding components. If they are not, right-click die, and then select component > die. Do
the same for the binder and punch.
6. On the tree, under Tools > Binder > Loads > Force: Force1, select Force:-1000.0, and then
select the value -1000.0. Change the value to -250000.0, and then press Enter.

Stage 3: Trimming

1. Select the Setup tab, and then double-click the trimming tool: .

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 The trimming tool appears in the Process Sequence:

2. On the tree, right-click , and then select Details. The Stage 3 tab opens and displays the
trim settings.
3. Select File > Import > Geometry.
4. On the the Import tab that appears, navigate to the file: <install_directory>/tutorials/mfs/
hf/Incr/multistage_trim_line.iges, and then select Import.
The geometry appears on your screen.
5. On the Import tab, click Close to return to the Stage 3 tab.
6. On the tree under Blanks > Blank, right-click Trim Lines, and then select New.
7. Right-click Trim Line 1, and then select Select Lines...
8. In the graphics area, select the trim line on your screen, and then click proceed.

9. On the tree, right-click Trim Line1, and then select Outside.

Simulating
1. Select the Stage 1 tab. Moving to the this tab ensures the simulation starts from Gravity.
2. Select the Setup tab.
3. On the tree, right-click MultiStage > Run Live. A pop up dialog appears asking if you want to run
the process from Stage 1. Click Yes.

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The simulation of the multi-step forming sequence begins.

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HF-3030: Post Processing Forming Results in HyperView

During a HyperView session, you can access the HyperForm Utilities menu which includes all of the
relevant features for post-processing stamping results.

Loading the HyperForm Utilities Menu

1. Launch HyperView.
2. Select File > Load > Preference File.
3. From the Preferences dialog that appears, select HypeForm Utilities, and then click Load.
The HyperForm Utilities menu loads into HyperView and appears on the toolbar between Preferences
and Applications.

Using the HyperForm Post-Processing Options

Distance Between Objects

This option calculates the distance between any two objects.

1. Select File > Open > Model.
2. Below the graphics area, for the Load model field, navigate to the results file: FormA001.
The file loads in both the Load model and Load results fields.
3. Click Apply.
4. To move to the last step of the simulation, on the animation toolbar, click the last option:

5. In the tree of the Model browser, under Components, click next to Punch and Blank Holder.
The Punch and Binder display turns off in the model graphics.
6. From the toolbar, select HyperForm > Distance Between Objects. The Distance Between
Objects dialog appears with the Component button for Part activated with a cyan border. If the

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 button is not activated, click it.

7. In the graphics area, select the Blank component in the model.

8. From the Distance Between Objects dialog, for Reference, click the Component button.
9. In the graphics area, select the Die component in the model.
10.From the Distance Between Objects dialog, click Calculate.
The screen splits into two halves, and a distance plot appears as you see next. The plot shows the
distance of every node of the part with respect to the die. The blank thickness for this part is
1.2mm. A gap of 0.6mm is allowed between the part and the die.

11.On the dialog, click Close.

12.On the toolbar, select Shaded Elements.

13.On the toolbar, select the Contour tool .

14.From the Contour options that appear, select the Legend tab, and then clear Max and Min.

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 15.Click Edit Legend.
16.On the Edit Legend dialog, in the legend, select the top value, enter 1.2, and then press Enter.

Blank–Tool Gap

This option displays the gap between the blank and tools at any given time step.
1. In the tree of the Model browser, under Components, click next to Punch.
The Punch display turns off in the model graphics.
2. To move to the last step of the simulation, on the animation toolbar, click the last option:

3.

4. Select HyperForm > Blank–Tool Gap, and the Blank-Tool Gap dialog appears.
5. Rotate the model to a convenient orientation and select the formed part.
6. On the Blank-Tool Gap dialog, click Calculate.
7. The HyperView window splits into two and shows a distance contour between the nodes of the
blank elements and the surrounding tools.

FLD

This option calculates the Forming Limit Diagram. The FLD is a measure to predict the formability
of a stamped part. The FLD is represented on graph with Minor strain on the x axis and Major strain
on the y axis.

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The FLD calculation can be based on the following input:
The hardening coefficient (n) from the material inputs and the blank thickness.
A user-defined Forming Limiting Curve, FLC.
Values defined for the major and minor strain to draw the FLC.

The following exercise is based on the first method, the hardening coefficient (n) from the material
inputs and the blank thickness.
1. Select File > Open > Model.
2. Below the graphics area, for the Load model field, navigate to the results file: FormA001.
3. Click Apply.
4. To move to the last step of the simulation, on the animation toolbar, click the last option:

5. In the tree of the Model browser, under Components, click next to Punch and Binder.
The Punch and Binder display turns off in the model graphics.
6. From the toolbar, select HyperForm > FLD. On the FLD dialog that appears, click Add.
A new study is added. The default FLC Math values are n: 0.20 and t: 1.0. Keep these default
values which are the inputs for the results selected.
7. Click Apply. The screen splits into two with the FLD in one half.
8. Click the FLD tab, and then click Apply. The FLD appears as follows:
Each point on the FLD represents an element on the stamped part.
Points are plotted based on the major and minor strains that a corresponding element is
subjected to during the stamping process.
The plot indicates that the part is possible to manufacture if no points appear in the red zone.
Points in the blue zone indicate a tendency toward thickening.

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Section Cut

This option shows the blank thickness of a user-created section of a part at a desired time step. A
contour and graph are displayed with the blank thickness on the y axis and the draw distance on the x
axis. The animate controls let you automatically update the graph.
1. From the toolbar, select File > Open > Model.
2. Below the graphics area, for the Load model field, navigate to the results file: FormA001.
3. Click Apply.
4. To move to the last step of the simulation, on the animation toolbar, click the last option:

5. From the toolbar, select HyperForm > Section Cut, and the Plot Section dialog appears:

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6. On the model in the graphics, area, click the Blank component.
7. From the Plot Section dialog, click Isolate. The tools on the model become masked.
8. From the Plot Section dialog, under Create Section, select an axis, and then click Base.
9. Click the longer axis of the Blank as you see in the following figure:

10.Under Select start and end, click the Nodes button.

11.Click a node on each edge of the long surface of the blank as you see in the following figure:

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 A cut appears across the blank.
12.On the Plot Section dialog, click Plot.
The screen splits into two halves with a graph in the second half as you see in the following figure:

13.Click Close.

Draw-In Plot

This option gives the distance between any point on a blank’s edge from a staring point to a current
position. The option is one of the measures for comparing a simulated part shape to test data.
1. From the toolbar, select File > Open > Model.
2. Below the graphics area, for the Load model field, navigate to the results file: FormA001.
3. Click Apply.
4. To move to the last step of the simulation, on the animation toolbar, click the last option:

5. In the tree of the Model browser, under Components, click next to Punch and Blank Holder.
The display of the Punch and Blank Holder is turned off in the model graphics.
6. From the toolbar, select HyperForm > Draw-in Plot. The Draw-in Plot dialog appears.
7. For Select the blank, click the yellow Component button. Component is activated and is
highlighted with a cyan border.
8. On the model in the graphics area, click the Part component.
9. From the Draw-in Plot dialog, under Select the binder/die, click the yellow Component button.
10. On the model in the graphics area, click the Die component.

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 The plot window splits into two with the Draw-In Plot window on the right.
11.In the Draw-In Plot window, click the edge of the part shape to plot the distance of that point from
its initial position. The image below shows the draw-in values for Magnitude, x and y.

12.On the Draw-in Plot dialog, click Close.

Tensor Plot

This option lets you plot the strain tensor for each element representing major and minor axes. The
operation is equivalent to the deformation directions obtained for the circle grid analysis.
1. From the toolbar, select File > Open > Model.
2. Below the graphics area, for the Load model field, navigate to the results file: FormA001.
3. Click Apply.
4. To move to the last step of the simulation, on the animation toolbar, click the last option:

5. In the tree of the Model browser, under Components, click next to Punch, Die, and Blank
Holder.
The display of the Punch, Die and Blank Holder is turned off in the model graphics.
6. From the toolbar, select HyperForm > Tensor Plot. The Tensor Plot appears:

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Export H3d

H3d is the abbreviation for Hyper3d, the HyperView portable binary result file. The Export H3d
option exports the current contoured result as an H3d file. You can view this file with the
HyperView player which is a free to download from http://www.altairhyperworks.com/
ResourceLibrary.aspx?category=Free%20Software%20Downloads

Export STL

This option lets you export the shape of a part at any desired time step as an STL mesh file.

Publish Report

This option lets you publish an HTML report with Deformation, %Thinning, Plastic Strain and FLD
results.
1. From the toolbar, select File > Open > Model.
2. Below the graphics area, for the Load model field, navigate to the results file: FormA001.
3. Click Apply.
4. To move to the last step of the simulation, on the animation toolbar, click the last option:

5. In the tree of the Model browser, under Components, click next to Punch and Blank Holder.
The display of the Punch and Blank Holder is turned off in the model graphics.
6. From the toolbar, select HyperForm > Publish Report, and the Publish Report dialog appears.

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7. For Select the blank, click the yellow Component button. The Component button is activated
and highlighted with a cyan border.
8. In the model graphics, click the Blank component.
9. In the Publish Report dialog, for Result Types, select one or more of the given options:
Deformation, % Thinning or Plastic Strain.
10.Under Export Options: select JPEG.
11.Click Publish, and an HTML file appears.
12.Click Close to close the Publish Report dialog.

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HF-3010: Simple Draw Forming

This tutorial teaches you how to set up a basic draw forming analysis with a simple box forming
example.

Prerequisites
Familiarity with basic HyperMesh functionality such as geometry cleanup, meshing, and mesh editing.
To learn more about these functions, see the HyperMesh tutorials in the online help.

Exercise: Basic Draw Forming Analysis

This exercise uses the model file forming.hf.

Tools

The following options are used in this tutorial can be accessed from the Setup menu:
Sections panel
Materials panel
Components panel
Tool Build panel
Tool Motion panel
Tool Loads panel
Save panel
Run panel

Step 1: Load the HyperForm file

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1. Click on and browse the directories to find the file <installation_directory>\tutorials\mfs
\hf\incremental\forming.hf.
2. Click Open.

Step 2: Create blank section properties

1. Click Setup > Sections.

2. In the section: field, type blank_section.
3. In the thickness= field, type 1.0.
4. Click card image: and select the respective card image from the list.

Note: For RADIOSS select SH_ORTH as the card image.

For LS-DYNA, select SectShll as the card image.

5. Click create.
6. Click return.

Step 3: Create blank material properties

1. Click Setup > Materials.

2. In the material: field, type CRDQ_steel.
3. Click card image:, and select the respective card image from the list:

Note: For RADIOSS select HillOrthotropic Tabulated as the card

image.

For LS-DYNA, select TransAnsioElasticPlastic as the card

image.

4. Click import curve.

5. In the curve: field, type stress_strain_curve.
6. In the sigy = field, enter 185. (MPa)
7. In the k = field, enter 550. (MPa)
8. In the n = field, enter 0.21.
9. Click create.
10.Click back.

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11.Click create.
12.Click on add to database. A folder browser appears allowing you to browse for a folder into which
the newly created material file will be saved. This is a one time operation for every new material
created, after which you can access the material using the Material Database option under the
Setup menu.

13.Click OK to close the folder browser.

14.Click return to close the Materials panel.

Step 4: Assign section and material properties for the blank component

1. Click Setup > Components.

2. Double-click component: and select blank.
3. Click section: and select blank_section.
4. Click material: and select CRDQ_steel.
5. Select the adaptive checkbox.

Note:

For RADIOSS: By default a maximum of two levels of

adaptivity are enabled and the initial value is set to 0.
If the starting element size in the blank is, for
example, approximately 8 mm, the smallest element
after maximum refinement will be approximately 2

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 mm. The adaptive levels can be changed by using
the Control Cards panel, and editing the
AdaptiveGlobalMesh card. The parameter to edit is
LevelMax. Refer to the RADIOSS Starter Manual for
more detailed information.
For Dyna: By default a maximum three levels of
adaptivity are enabled. In Dyna, the initial level is
considered as level 1. If the starting element size in
the blank is, for example, approximately 8 mm, the
smallest element after maximum refinement will be
approximately 2 mm. The adaptive levels can be
changed by using the Control Cards panel, and
editing the Adaptive card. The parameter to edit is
MAXLVL. Refer to the Dyna manual for more detailed
information.

6. Click update.
7. Click return.

Step 5: Display only the die component

1. In the Model Browser, expand the Component folder.

2. Right-click on the Component folder and select Hide.
3. Right-click on the die component and select Show. The die component appears on the screen.

Step 6: Build the punch and binder components

1. Click Setup > Tool Setup.

2. Select the Build and setup tool from DIE surface subpanel.
3. For Machine Type, choose Double acting.
4. Click on the yellow Elements button in the Binder Source: field. The element selector panel
appears.
5. Click elems and select on plane.
6. If necessary, click the switch to the N1, N2, N3 and B option. Pick four nodes on the binder for
N1, N2, N3 and B as shown below.

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7. Click Select entities, and then select proceed.
8. Click Build. This will extract the punch and binder surface from the die cavity.

9. Click Close.

Note:

Note after execution, binder and punch components are

generated. The punch offset amount is set using the blank
thickness value. The punch offset is calculated to be thickness
plus 20 percent (Default tolerance). In this case, it is 1.1*2.0
mm = 1.2 mm.
This Tool Build macro creates blank and tool sections and
tool materials. In case these are already created, it will be
updated.
It also creates 3 contacts viz between blank-die, blank-punch
and blank-binder.

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Step 7: Set a top view of the blank

1. In the Model Browser, for each component, click on the mesh icon to turn the mesh display off
in the model for all components except blank.

2. From the toolbar, click the user view icon.

3. Click top.

Step 8: Define symmetry plane constraints

1. Click Setup > Symmetry Plane.

2. Under Select symmetry plane, select YZ.
3. Click create. The node selector panel appears.
4. Pick a node on the symmetric plane of the blank (right-hand edge).
5. Click proceed.
6. Click Close.

Step 9: Set an iso view and display all the components

1. From the toolbar, click the user view icon.

2. Click iso 1.
3. Using the Model browser, click on the mesh icons on the components to turn their display back on.

Step 10: Define the tool motion

1. Click Setup > Tool Motion.

2. Click moving tool and select the punch component.
3. Verify all options (on the right-hand side) are set to
translation

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 velocity
linear
termination, load curve and loadcol are also checked.
4. Click max velocity and type –5000. (mm/s)
5. Click total travel and type 69.2. (mm)

Note:

The total travel is distance the punch travels to close in on the

die. This value is the distance between the punch and die,
minus the blank thickness and a tolerance (Default is set to
20% of blank thickness). This distance between the punch
and die are calculated using the Distance (F4) panel (Try to
select, identical nodes on the die and punch).
Total Travel = Distance Punch to Die – (Blank thickness +
20% Blank Thickness)
Total Travel = 70.4 – (1.0 + 0.2) = 69.2

6. Click set up.

7. Complete the following steps for Dyna only:
Click the history subpanel on the left.
Click cycles/travel and type 500. (cycles / mm of tool travel)
Click update.
Notice timestep is changed to 4.000e-7. The following message appears: "history was updated
successfully."
Click motion.
Click update.
8. Click return.

Step 11: Define the binder load

RADIOSS

1. From the Setup menu, click Tool Load.

2. Click tool = and select Binder.
3. Click tool force and type -100000. (N)
4. Under setup option: make sure both load curve and CLOAD_Collector are checked.
5. Click setup.

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 6. Click return.

LS-DYNA

1. From the Utility Menu, under Setup, click Tool Load.

2. Click tool = and select Binder.
3. Click tool force and type -100000. (N)
4. Click max velocity and enter 500. (mm/s)
5. Click setup. The following message appears: "Tool load was set up successfully."
Note: A force of 100kN is applied to the binder. A rigid body stopper limits the maximum
velocity of the binder in order to minimize inertial effects. For more information about
rigid body stopper, refer to HyperForm's FAQ section.
6. Click return.

Step 12: Save the analysis setup as forming_complete.hf

1. From the File menu, click Save As....

2. Use the file browser to save the file as forming_complete.hf.
3. Click Save.

Step 13: Review the animation and run the analysis

RADIOSS

1. From the Setup menu, click Run Analysis.

2. Click create sta file.

Note: At the end of the computation, RADIOSS will write out a file called "sta". This file
contains all the thickness, stress and strain information necessary to perform
subsequent operations. This file is essential for performing multi-stage setups.

3. Click animation.

Note: Animation feature enables you to review and correct the tool motion.

4. Click run to start the computation in RADIOSS.

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LS-DYNA

1. From the Utility Menu, under Setup, click Run.

2. Click create dynain.
3. Click applied comps:comps and select blank.
4. Click select.
5. Select the DYNA checkbox to enable DYNAIN output.
6. Click setup. A message appears stating: "Dyna3d was set up successfully."

Note: At the end of the computation, Dyna will write out a file called "dynain". This file
contains all the thickness, stress and strain information necessary to perform subsequent
operations. This file can be read directly by HyperForm and is essential for performing
multi-stage setups.

7. Click return.
8. Click animation.

Note: This animation feature enables you to review and correct the tool motion.

9. Click dyna file and type forming_complete for the name.

10.Click run. A Dyna input file named forming_complete.bdf is generated. The file can be
submitted to Ls-Dyna.

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HF-3020: Combined Binderwrap and Draw Forming Analysis

This tutorial illustrates a combined binderwrap and draw forming setup procedure. A setup file
containing the die mesh provides a starting point. All tool components are generated from the die tool
mesh. Appropriate material and section properties are assigned to each component.
In this tutorial, you will learn about:
Double action forming processes
Importing a HyperForm file
Birth and death time concepts

Exercise: Performing a Combined Binderwrap and Draw Forming Analysis

For this exercise, use the following files based on your user profile:
RADIOSS: bwrap_form_Radioss.hf
LS-DYNA: bwrap_form_.hf
RADIOSS and LS-DYNA: bwrap_form_blank.hf

Tools

The options you will use for this tutorial are located on the Setup menu. The options include:
Sections panel
Materials panel
Comps panel
Tool Build panel
Tool Motion panel
Tool Loads panel
Save panel
Run panel

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Step 1: Load the File

1. Click and navigate to file indicated for your user profile:

RADIOSS Incremental: <installation_directory>\tutorials\mfs\hf\incremental
\bwrap_form_Radioss.hf
LS-DYNA: <installation_directory>\tutorials\mfs\hf\incremental/bwrap_form_.hf
2. Double-click the file to load it into your session.

Step 2: Import a Second File

1. To open the Import dialog, click .

2. Click the Import HM Model icon .

3. From open the file bwrap_form_blank.hf, and then click Import.

Note: Import loads the file into the current session without
erasing the existing file. Load model loads the model into
the current session and erases the existing file.

4. Click Close to close the Import dialog.

Step 3: Create blank section properties

1. Click Setup > Sections, and then for section, enter blank_section.
2. For thickness, enter 1.0 (mm).
3. Select a card image, and then click create:
For RADIOSS, select SH_ORTH.
For Dyna, select SectShll.
4. Click return.

Step 4: Create Blank Material Properties

1. Click Setup > Materials. The Material definition panel displays.

2. Click material, and then enter CRDQ_steel.

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3. Click card image, and then select a card image:
For RADIOSS, select HillOrthotropic Tabulated.
For LS-DYNA, select TransAnisoElasticPlastic.
4. Click import curve.
5. Click curve: and enter stress_strain_curve.
6. Click sigy = and enter 185 (MPa).
7. Click k = and enter 550 (MPa).
8. Click n = and enter 0.21.
9. Click create.
10.Click back.
11.Click create.
12.Click add to database, and then in the dialog that opens, specify a directory in which to save the
newly created material file. Note that you must specify a directory for each new material you
create, after which you can access the material using the Material Database option in the Setup
menu.

13.Click OK to close the folder browser.

14.Click return to close the Materials panel.

Step 5: Assign Section and Material Properties to the Blank Component

1. Click Setup > Components.

2. Double-click component >> blank.

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3. Click section >> blank_section.
4. Click material >> CRDQ_steel.
5. Select the box: adaptive.
6. Click update, and then return.

Note: By default, two levels of adaptivity are enabled. If the

starting element size in the blank is, for example,
approximately 8 mm, the smallest element after maximum
refinement will be approximately 1 mm. You can change the
adaptive levels by editing the AdaptiveGlobalMesh card in
the Control Cards panel. The parameter to edit is LevelMax.
For more information, see the RADIOSS Starter Manual.

Step 6: Display a Top View of the Die Component Only

1. Click the Model tab to display the Model Browser or click View > Model Browser.
2. Expand the Component folder.
3. Click the mesh icon as shown in the figure below to turn off the blank mesh.

4. On the toolbar, click the user views icon and select top.

Step 7: Build the Punch and Binder

1. From the Preferences menu, select Meshing Options.

2. Click feature angle and enter 2.0 (degrees).
3. Click return.

Note: Changing the feature angle to 2.0 will make element

selection on the binder area easier.

4. From the Setup menu, select Tool Setup.

5. Select the Build and setup tool from DIE surface subpanel.
6. For Machine Type, choose Double acting.

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7. In the Binder Source: field, click Elements. The element selection panel is displayed.
8. Select one element on the binder area of the die, as shown below.

Figure 1: Element to select

9. Click elems and select by face option from the extended entity selection. This highlights all the
elements on the binder area of the die, as shown below.

10.Click proceed.
11.Click Build.
12.Click Close.

Note:

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 Notice after executing the build, the binder and punch
components are generated. The punch offset amount is set
using the blank thickness value. The punch offset is calculated
to be thickness plus 10 percent. In this case, it is 1.1*1.0 mm
= 1.1 mm.
The Tool Build macro creates tool sections and tool materials.
If these were already created, they are updated.
This macro also creates 3 contacts viz between Blank-Die,
Blank-Punch and Blank-Binder.

Step 8: Define the Tool Motion for the Binder

1. Click Setup > Tool Motion.

2. Click moving tool and select the binder component.
3. Click max velocity and type –2000 (mm/s).
4. Click total travel and type 5.7 (mm).

Note: The total travel of the binder is the distance the binder has
to travel rest on the die holding the blank. This value is the
distance between the binder and die, minus the blank
thickness and a tolerance (typically 10-20%). This distance
between the binder and die are calculated using the Distance
(F4) panel. (Try to select identical nodes on the die and
binder).

Total travel - Distance Binder to Die - (Blank thickness + 20%

Blank Thickness)

Total travel = 6.9 - (1.0 + 0.2) = 5.7

5. Verify all options (at right hand side) are set to:
translation
velocity
linear
termination, load curve and loadcol are also checked.
6. Click set up.
7. Click the history subpanel.
Note the calculated termination time is T = 4.850e-03 seconds. This time will be used again later
in the exercise.
8. Click the motion subpanel.

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9. Click edit card.
For RADIOSS, click Tstop field and enter 4.850e-03 (s).
For Dyna, click DEATH time field and enter 4.850e-03 (s).
This is the time at which the prescribed motion of the binder is killed, and is also the time at which
the force load is applied to the binder later in this exercise.
10.Click return.
11.Click update.

Step 9: Define the Punch Tool Motion

1. Click moving tool and select the punch component.

2. Click max velocity and enter –5000 (mm/s).
3. Click total travel and type 76.0 (mm).

Note: The total travel is distance the punch travels to close in on

the die. This value is the distance between the punch and the
die, minus the blank thickness and a tolerance (typically 10-
20 percent). This distance between the punch and die are
calculated using the Distance (F4) panel. (Try to select
identical nodes on the die and punch.)

Total Travel = Distance Punch to Die - (Blank thickness + 20

percent Blank Thickness)

Total Travel = 77.2 - (1.0 + 0.2) = 76.0

4. Click starting time and enter 4.850e-03 (s).

5. Select the termination check box to uncheck it.
6. Click set up.
7. For Incremental_Dyna only, complete the following steps:
Click the history subpanel.
Click cycles/travel and enter 100 (cycles/mm of tool travel).
Click update. Notice that the timestep is reduced from 4e-7 to 2e-6.
8. Click return.

Step 10: Define the Binder Load

For Incremental RADIOSS user profile:

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 1. From the Setup menu, select Tool Load.
2. Click tool = and select Binder.
3. Click tool force and type -200000 (N).
4. Verify that load curve and CLOAD_Collector are selected.
5. Click setup.
6. From the Setup menu, select Curves Editor.
7. Select the curve CLOAD_curve-binder and enter 4.450e-03 as the first entry of the X axis as
shown below:

4.450e-03 -200000.0
1.0 -200000.0

8. Click on Update.
9. Click on Close.
10. Click return.

For Incremental Dyna user profile:

1. From the Utility Menu, under Setup, click Tool Load.

2. Click tool = and select Binder.
3. Click tool force and type -200000. (N)
4. Click max velocity and type 500. (mm/s).
5. Click birth time and type 4.450e-03 (s).
Verify that Load curve, loadrigbod and stoppers are all selected.
6. Click setup.
A force of 200kN is applied to the binder. A rigid body stopper limits the maximum velocity of
the binder in order to minimize inertial effects. This rigid body stopper is defined to be active
(note birth time) only after the prescribed motion of the binder has been killed. For more
information about rigid body stopper, refer to the FAQs in the HyperForm online help.
7. Click return.

Step 11: Update the Tool Type for Die

1. Click Setup > Components.

2. Click component and select die.
3. Click section and select tool_sec.

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4. Click material and select CRDQ_steel.
5. Select the rigid checkbox.
6. Click update.

Step 12: Save the Analysis

1. From the File menu, click Save As....

2. Save the file as bwrap_form1_radioss_complete.hf for RADIOSS and bwrap_form1_complete.hf
for LS-DYNA.
3. Click save.

Step 13: Review the Animation and Run the Analysis

1. From the Setup menu, select Run Analysis.

2. Click animation.
Note: Notice the kinematics of the tool motion. This animation feature enables you to review and
correct the tool motion.
3. Click run to start the computation in RADIOSS.
For LS-DYNA: An LS-DYNA input file named bwrap_form1_complete.bdf is generated. The file can be
submitted to LS-DYNA for solver analysis.

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HF-3030: Drawbead

In this tutorial, you will learn:

How to apply analytical drawbeads in a simple box forming process
How to define tool motion
About birth and death time concepts in tool motion definition
How to define tool load

Exercise: Using Analytical Drawbeads

This exercise uses the model file drawbeads_Radioss.hf and drawbead_lines.igs for RADIOSS setup
and drawbeads.hf and drawbeads_lines.igs for LS-DYNA setup.

Tools

The following panels are used in this tutorial and can be accessed from the Setup menu:
Sections panel
Materials panel
Comps panel
Tool Build panel
Tool Motion panel
Tool Loads panel
Save panel
Run panel
HyperForm provides two methods by which to setup analytical drawbeads:
The drawbead function, from the Setup menu of the Incremental_RADIOSS/Incremental_LS-
DYNA user profiles.
The Drawbeads Editor module, from the Setup menu of the Incremental_RADIOSS/
Incremental_LS-DYNA user profiles.

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Step 1: Load the File

1. Click the icon and browse the directories to select the file <installation_directory>
\tutorials\mfs\hf\incremental\drawbeads_radioss.hf for Incremental_RADIOSS and
<installation_directory>\tutorials\mfs\hf\incremental\drawbeads.hf file for
Incremental_LS-DYNA.
2. Click Open.

Step 2: Translate the Binder

1. Click Mesh > Translate > Components.

2. Click comps, and then select the Binder component.
3. Set the direction switch to z-axis.
4. Set the toggle to magnitude = and enter 6.0.
5. Click translate +.
6. Click return.

Note: The binder is translated in the z-direction to account for the

addition of analytical drawbeads of height 6.0 mm.

Step 3: Import the Drawbead IGES Line

1. Click Import to open the tabbed Import dialog.

2. Click Import Geometry to set the Import Geometry options.

3. Click and open the file: <installation_directory>\tutorials\mfs\hf\incremental

\drawbead_lines.igs.
4. Click Import to import the file.
5. Click Close to close the Import dialog.

Step 4: Display Only the Die Component and Change the Visualization to Wire
Frame Mode

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1. In the Model Browser, expand the Component folder.
2. Click the mesh icon as shown in the figure below to turn off the mesh display for all components
except the blank mesh.

Display the binder and drawbead lines

3. Click to change the visualization to wire frame mode.

Step 5: Create Analytical Drawbeads

1. Click Setup > Drawbeads.

2. For drawbead: enter db1.
3. Click comps, and then select the blank component as the master.
4. Click line, and then select the line for DB1, as shown in the following figure:

For Incremental_Dyna only, click attached to, and then select binder.
5. Click calculate to switch to the drawbead force calculator. Notice that Drawbead height and
radius are automatically set to 6.25.
6. For shoulder radius, enter 2.0.

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7. Ensure that Round is selected as the Drawbead type.
8. Click calculate. Notice that restraint force and closure force are automatically calculated.
9. Click back to accept calculated values.
10.Click color, and then select a color.
11.Click create to generate the drawbead. Notice a thick line drawn in your selected color appears on
the blank.

Step 6: Create Additional Drawbeads

1. For drawbead enter: db2.

2. Click comps, and then select the blank component as the master.
3. Click line, and then select the line for DB2, as shown in the figure in the previous step.
4. Click color, and then select a color.
5. Click create.
6. For drawbead, enter the name db3.
7. Click comps, and then select the blank component as the master.
8. Click line, and then select the line for DB3, as shown in the figure in the previous step.
9. Click color, and then select a color.
10.Click create.
11.Click return. Note the following components are created depending on your user profile:
RADIOSS: Three components are created for drawbeads with the names ^db_line for [user
input name]. /INTER/TYPE8/INTER ID RADIOSS cards are created and stored in
those components.
LS-DYNA: Three components are created for drawbeads with the names ^db_line for [user
input name]. *Contact_Drawbead_Title DYNA cards are created and stored in those
components.

Step 7: Display All Components and Set View to Isometric

1. From the Model Browser, click the mesh icon to turn off the blank mesh:

2. Type v on the keyboard to open the view menu.

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3. Click Iso1.
4. From the Model Browser, right-click the Component folder, and then select Show.

Step 8: Define the Binder Tool Motion

1. From the Setup menu, click Tool Motion.

2. For moving tool, select the Binder component.
3. For max velocity, enter –2000.
4. For total travel, enter 6.0.
5. Verify that the options on the right are set to:
translation
velocity
linear
termination, load curve and loadcol are also checked.

6. Click setup.
7. Click the history subpanel. Notice that the calculated termination time is T = 0.005 seconds.
This time will be used again later in the exercise.
8. Click the motion subpanel.
9. Click edit card.
10.For RADIOSS, for Tstop, enter 0.005. For LS-DYNA, for DEATH, enter 0.005.
The stop/death time ensures that the prescribed motion of the binder is stopped before a force
load is applied.
11.Click return.
Remain in the Tool Motion panel for the next step.

Step 9: Define the Punch Tool Motion

1. Click moving tool, and then select the Punch component.

2. Click starting time, and then enter 0.005.
The start time offset ensures that the punch does not start moving until the binder is fully closed.
3. Click update.
4. Click the history subpanel.
Note the termination time, T, is now calculated to be 2.090e-2 seconds.
For Incremental_Dyna only, complete the following steps:

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 Click cycles/travel, and then enter 100.
Click update, and then return.

Step 10: Define the Binder Load

RADIOSS Incremental

1. From the Setup menu, click Tool Load.

2. For tool =, select Binder.
3. For tool force, enter –100000.
4. Verify the direction is set to Z axis.
5. Click setup, and then return.

LS-DYNA Incremental

1. From the Setup menu, click Tool Load.

2. For tool =, select Binder.
3. For tool force, enter –100000.
4. Verify the direction is set to Z.
5. For max velocity, enter 500.
6. Click setup.
7. For the stoppers box, click edit.
8. For TB, enter 0.005 (s).
9. Click return.
The rigid body stopper becomes active as soon as the prescribed motion of the binder is killed.
10.Click update, and then return.

Step 11: Save the Analysis Setup as drawbead_complete.hf

1. From the File menu, click Save As...

2. Use the file browser to save the file as drawbead_Radioss_complete.hf for RADIOSS and
drawbead_complete.hf for DYNA.
3. Click Save.

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Step 12: Review the Animation and Run the Analysis

For RADIOSS Incremental

1. From the Setup menu, click Run Analysis.

2. Click create sta file.
3. Click animation. Notice the kinematics of the tool motion. This animation feature enables you to
review and correct the tool motion.
4. Click run to start computation in RADIOSS.

LS-DYNA Incremental

1. From the Setup menu, under Setup, click Run.

2. Select the box: create dynain.
3. For applied comps: comps, select blank.
4. Click select.
5. Select the box: DYNA.
6. Click setup.
7. Click return.
8. Click animation.
Notice the tools move showing the kinematics of the tool.
9. For dyna file, enter the name drawbead_complete.
10.Click run. The software generates the input file drawbead_complete.bdf, which you can submit
to the LS-DYNA solver for analysis.

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HF-3040: Redraw Forming Analysis from the User Process

This tutorial shows you how to set up the second stage of a forming analysis. The model files for this
tutorial are redraw_radioss.hf and cup_draw_001.sta.

1. Copy and unzip the following file to your working directory: <installation_directory>\tutorials
\mfs\hf\incremental\cup_draw_001.zip.
2. In the tree of the User Process tab, right-click Blanks, select From File..., browse to
cup_draw_001.sta, and then click Open.
A formed part appears on your screen. In the tree, under Blanks, Blank 1 loads with material and
thickness information.
3. From the File menu, select Import > Model.
4. On the Import tab under File selection, browse to redraw_radioss.hf, and then click Import.
A part appears on your screen.
5. Click Close.
The Import tab closes and the User Process tab opens.
6. Near the top of the tree, right-click Process: Type > Forming > Single Action.
7. Right-click Process: Single Action Draw, and then select Autoposition.
Notice that the tools are positioned with respect to the part, and the tool kinematics are updated.
8. Under Tools > Binder, click Force:1000.0, click the value, 1000.0, enter the value -150000, and
then press Enter.
The new value applies ~15 tons in the negative z direction.
9. At the top of the tree, right click Process: Single Action Draw > Run.
10.At the prompt to create input, click Yes.
11.In the dialog that appears, browse to your working folder, for File name, enter Redraw, and then
click Save.
The RADIOSS solver launches.

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HF-3050: Gravity

This tutorial teaches you the setup procedure for performing a gravity analysis through the User Process
utility. The setup for the example model includes:
Positioning the blank with reference to the die.
Assigning the appropriate material and section properties to the tool and blank.
A setup file containing the blank and die mesh provides the starting point.

Exercise: Set Up a Gravity Analysis from the User Process

This exercise uses the model file gravity.hf.

1. From the File menu, select Open.

2. Browse to the file <installation_directory>/tutorials/mfs/hf/incremental/gravity.hf, and
then click Open.
3. Near the top of the tree, right-click Process Type, and then select Gravity.
4. Under Blanks > blank, right-click Material, select database > steel > CDRQ, and then click
Select.
5. Click Thickness:1, and then click the value :1 to make the field editable. Enter the blank thickness
1.25.
6. At the top of the tree, right-click Process: grav_implicit, and then select Autoposition...
Notice that the blank positions itself with respect to the die.
7. Right-click Process: grav_implicit, and then select Run.
8. At the prompt to create input, click Yes.
9. In the dialog that appears, browse to your working folder, for File name, enter a file name, and then
click Save.
The RADIOSS implicit solver launches and runs the gravity computation.

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HF-3060: Trimming

This tutorial teaches you the setup procedure for a trimming operation on a simple box form. The part
shape, stress, and strain state at the end of a draw-forming operation are the inputs for this analysis.

Exercise: Trimming Analysis from the User Process

This exercise uses the files trim_line.igs and radios_trimming_sta (zipped as
Radioss_trimming.zip) located in the installation directory.

Note: You can select either elements or components to indicate the area for the trimming operation.
Selection by components removes only the elements inside of the trim line.

1. Copy and unzip the following file to your working directory: <installation_directory>\tutorials
\mfs\hf\incremental\Radioss_trimming.zip.
2. On the bottom of the tree in the User Process, right-click Blanks, select From File..., browse to the
file radios_trimming_sta, and then click Open.
The file loads and the model is displayed in the graphics area on your screen.
3. Click File > Import > Geometry.
4. On the Import tab that opens, for File type, select IGES, browse to the file
<installation_directory>\tutorials\mfs\hf\incremental\trim_line.igs, and then click
Import.
The trim line for your model is imported.
5. Select Close.
6. Near the top of the User Process tree, right-click Process Type, and then select Trimming.
7. Under Blanks > Blank1, right-click Trim Lines, and then select New.
8. Right-click Trim line 1, and then select Select Lines...
9. Under trim_line.igs, verify that the Remove:Inside option is selected.
10.To trim the part, right-click Process: Trimming, and then select Create Input.
11.In the dialog that appears, browse to your working folder, for File name, enter a file name, and then
click Save.

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Note: For RADIOSS, trimming is performed with HyperForm and the trimmed blank is saved with
the specified file name. For LS-DYNA, the solver is launched to create the trimmed blank.

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HF-3070: Springback

During a forming process, the elasto-plastic stress gradients across the surface build up and result in
accumulation of residual stresses. The residual stresses cause the material to bounce back after forming.
The resulting deviations from the profile often require manual adjustment before the component is
considered acceptable for assembly. Components that do not fit in the final assembly usually need
additional shimming and assembly time.
This tutorial teaches you the setup procedure for performing a springback analysis. The part-shape and
stress-and-strain states at the end of a simple draw forming operation are the inputs to the setup and
are available in the STA file. Appropriate material and section properties are assigned to the blank
component.

Exercise: Setup Springback from the User Process

This exercise uses the file radios_springback_sta (zipped as Radioss_springback.zip) located in the
installation directory.
1. Copy and unzip the following file into your working directory: <installation_directory>\tutorials
\mfs\hf\incremental\Radioss_springback.zip.
2. On the bottom of the tree in the User Process, right-click Blanks, select From File..., browse to the
file radios_springback.sta, and then click Open.
The file loads and the model is displayed in the graphics area on your screen.
3. At the top of the tree, right-click Process Type, and then select Springback.
4. Under Blanks, right-click Material, and then select Database…. The Material Database dialog
appears.
5. In the Steel folder, click CRDQ, and then click Select.
6. At the top of the tree, right-click Process: Springback, and then select Run.
7. At the prompt that appears, select Yes.
8. In the dialog that appears, browse to your working folder, for File name, enter a file name, and then
click Save.
The RADIOSS implicit solver launches and runs the springback computation.

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HF-3080: Hot Stamping

The steps in this tutorial are similar to those for a single-action-draw analysis, with the involvement of
temperature for forming sheet metal. The exercises show you how to set up an arbitrary stamping
process from scratch with the User Process.
Benefits of the of User Process
Set up unique forming processes and save them as templates that can be retrieved and reapplied
with minimal or no input.
Flexibility to include any number of tools.
Flexibility for different tool orientation.
Tool kinematics that do not need to follow the conventional forming types, such as Single Action
Draw and Double Action Draw.
During the setup of a model in the Auto Process, the model definition is captured by the User
Process.

Exercise 1: Performing a Thermal Forming Analysis with the User Process

This exercise uses the model file hot_forming.hf.

Step 1: Load the file

1.Click and browse to the file: <installation_directory>\tutorials\mfs\hf\incremental

\hot_forming.hf.
2.Double-click the file to load it into the session.

Step 2: Arrange the components

After opening the model for the first time, the User Process groups all of the components into the
Blanks category. The following steps show you how to move the components into the the correct
categories.
On the tree of the User Process, right-click ProcessType: Forming, and then select Hot

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stamping > single action:

Step 3: Load the Single Action Draw Process

1. On the tree under Thermal, select Actual forming speed {mm/s}, click the current value, and
then enter the value 100. Note that temperature is in degrees Kelvin. Keep the default values for
the remaining thermal coefficients.
2. For Blank transfer time, enter 2.0.
3. For Tool approach time, enter 5.0.
4. For Quenching Time, enter 15.0.

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Step 4: Set up the Blank parameters

On the tree, select Initial Temp, click the current value, and then enter 1073, which is the usual
initial temperature for hot stamping.
Step 5: Set up the Tools parameters

Because you are using the standard action draw template, the defaults for the Tools parameters can
be kept as they are, with the exception of the Temp value.
1. On the tree, under Die, select Temp, click the current value, and then enter 373.
2. Do the same for the remaining Tool components.

Step 6: Prepare the model to run

1. Right-click in the white space of the User Process. From the context menu that appears, select
Autoposition.
The status of the auto positioning operation is displayed in the left, bottom corner of the
window. Done indicates that tools have been successfully positioned with respect to the blank.
2. To review the process sequence, click View > Process Sequence.
The Sequence tab displays the tool kinematics sequence.
The Messages tab displays the errors in the setup, if any.

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 3. After viewing the sequence, in the User Process browser, right-click and select Create Input.
4. Right-click again, and select Run.
5. Enter a desired name in the file browser, and then click Save. The run begins.

Exercise 2: Performing a Thermal Forming Analysis with the Auto Process

Another method of stepping through a thermal process is to use the Auto Process feature available in
the Incremental_RADIOSS user profile.

1. To save the existing file in the session, select File > Save As.

2. Click the New Model icon . The existing model is cleared from the session. Note that the
parameters in the tree are cleared.

3. Click and browse to the file hot_forming.hf. Double-click the file to load it into the session.

4. Above the graphics area, click Single Action Draw . The Auto Process panel appears:

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5. For Thermal Option, select On.
6. On the first row in the table, click Blank1, The row becomes activated.
7. For Initial temperature, enter the value 1073.
8. To change the CRDQ material assigned to the Blank, browse to the Material Database, and then
select Boronsteel-Kelvin.
9. Click the Die row to activate it. For Temperature, enter 373. Do the same for the Punch and
Binder.

10.Click the Details tab.

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11.Click Thermal option: On to see the list of thermal options.

12.For Room Temp, enter 298.

13.For Actual forming speed {mm/s}: enter 200.
14.To return to the main dialog, click the Setup tab.
15.Click Run, navigate to the directory where you want to save the results, enter a file name, and
then click Save.
The solver runs the simulation.

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HF-3090: Setting Up a Composite Forming Simulation

This tutorials shows you the steps to set up a composite forming analysis from the User Process and
post process the results in HyperView.
Benefits of the User Process
Enables the set up and capture of unique forming processes that can be saved as templates, and
later retrieved and reapplied with minimal or no input.
Flexibility to include any number of tools.
Flexibility to change the orientation of the tools.
Tool kinematics that are unrestricted to conventional forming types such as Single Action Draw and
Double Action Draw.
Captures the model setup from the Auto Process and loads it into the User Process from the model
definition.
Files
This tutorial uses the model file forming_userprocess.hf.

Step 1: Load the File

1. From the toolbar, select File > Open.

2. Browse to the file: <installation_directory>\tutorials\mfs\hf\incremental
\forming_userprocess.hf, and then click Open.

Step 2: Define Process Parameters

1. From the User Process tab, right-click Process Type, and then select Forming > Single
Action.

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 The options for a single-action process appear. In the tree, Under Settings, adjust the settings
as follows:
2. Right-click Blank Type, and then select Composite.
3. Under Blank Type, right-click Blank Config, and then select Sandwich.
4. Right-click Symmetry, and then select no.
5. Under Animation: Count, click Count 10, click the value 10, change the value to 15, and
then press Enter.
6. For Draw direction, keep the default: Z.
7. For Motion Mode, keep the default: Velocity.
8. For Memory Mode, keep the default: Automatic.
9. Right-click Adaptivity, and then select On.

Step 3: Set Up the Blank Parameters

1. Under Blanks, right-click Blank, and then select Add Ply. Repeat until you have four plies.
2. For Ply 1, Ply 2, Ply 3, and Ply 4, click Thickness: 1.0, click the value 1.0, change the value
to 0.5, and then press Enter.
3. For Ply 2 and Ply 4, click Angle: 0.0, click the value 0.0, change the value to 45, and then
press Enter.
4. From the top of the tree, right-click Process: Single Action, and then select Run.

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HF-3100: Post Processing Composite Forming Results in HyperView

This tutorial shows you how to post process the results of a composite forming simulation in HyperView.
Files
This tutorial uses the results file: CompositeA001.
1. Launch HyperView.
2. Below the graphics area, for the Result-Math template, select Advanced:

3. For the Load model field, navigate to the results file: CompositeA001.
The file loads in both the Load model and Load results fields.
4. Click Apply.
5. In the tree of the Model browser, select next to Rigid elements.
The display of Rigid elements is turned off in the model graphics.
6. From the animation controls, animate the model and observe the ply behavior.

7. In the tree of the Model browser, select next to the following elements: Resin1, Resin2, Punch,
Binder and Die.
The display of the selected elements is turned off in the model graphics. Only the plies are visible.
8. From the toolbar, select , and the Contour panel appears.
Note that for Result type, the following options are available for multilayer composite forming
simulations:
%Thinning-solids(s)
Fiber rotation (derived result)
Fiber orientation (derived result)
USR1 = Stresses in fiber1
USR2 = Stresses in fiber2
USR3 = Shear stress
USR4 = strain in fiber1
USR5 = Strain in fiber2

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 USR6 = tangent of shear angle
9. For Result type, select %Thinning-solids(s), and then click Apply.
The Nodal distance between the top ply and bottom ply for the last time step is displayed as a
contour, as you see in the following figure. This contour does not change with time.

10.From the Model browser, right-click, and then select Create > Derived Result:

11.In the Expression Builder that appears, populate the fields as follows:
For Label, enter Fiber Rotation.
For Table, select PHI.
Click Insert. At the bottom of the dialog, in the field under Expression, S4 appears.
For Show required, select the downward arrows.
For Layer, select None.
For Frame, select Time: 0.0000e+000.
In the field under Expression, enter a hyphen (-) after S4, and then click Insert. F1.S4 appears
next to the hyphen and the command reads: S4-F1.S4

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 Check that the fields in the Expression Builder look like the ones in the following figure, and then
click Apply.

12.Click OK.
On the Contour panel, a new Result type, Fiber Rotation(s), is added to the drop down menu.
13.For Result type, select Fiber Rotation(s).
14.In the Model browser, turn off Ply 2, Ply 3 and Ply 4.
15.In the Contour panel, for Layers, select Layer 1, and then click Apply.
The Fiber Rotation for Layer1 is displayed you see in the following figure:

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16.In the Model browser, right-click, and then select Create > Derive Result.
17.In the Expression Builder, select the options as you see in the following figure. In the editor under
Expression, copy and paste the following string:
VectorFromScalar(cos(S4),sin(S4),0.000000000000,"elem")

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18.Click OK.
A new result type called Fiber Orientation (s) appears under the contour and vector panel.
19.For Result type, select Fiber Orientation (s).
20.For Layers, select Layer 1.
21.On the Display tab, do the following:
For Size scaling, select By Magnitude and enter 1.0.
For Color by, select Direction.
22.Click Apply.
The Fiber Orientation is displayed for each element with a vector as you see in the following figure:

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HF-3110: Blank Optimizer

The exercises in this tutorial guide you through a blank optimization problem using the Blank Optimizer
tool, also known as Blank Opti.
Blank Optimization is a process you can use to precisely capture a final part profile after performing an
incremental forming analysis. The process includes three main steps:
1. Measure the deviation between the final part edge from the analysis and the targeted part edge,
and then apply the measurement to the original blank profile.
2. Generate a new blank shape based on the applied deviation.
3. Add or remove material in areas corresponding to deviations of the part edge with respect to the
target edge.

Exercise 1: Blank Optimizer Without Web Exclusions

This exercise uses the model files:

Incremental_RADIOSS:
BlankOptiFinal.STA
BlankOptiInitial.nas
BlankOptimize_TargetLine_Radioss.iges
Incremental_Dyna:
final-dynain
initial_dynain
BlankOptimize_TargetLine.iges
You do not have to load these files individually. When you start the Blank Optimizer, you need to
indicate your root directory. This root directory should contain the files mentioned above. The function
will load the appropriate model at the appropriate time in the task.

Tools

Blank Opti

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Step 1: Open the file and select the root directory

The model files are zipped in the tutorial location. Before proceeding, copy and unzip the files into a
working directory.
1. From the Tools menu, select Blank Opti > Select Root Directory.
A dialog opens with instructions about file formats and locations, as you see in the following
image:

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 Incremental_Dyna dialog

2. Click Proceed.
A dialog opens for you to change the exiting location of the root directory to the directory where
your model files are stored. Note that spaces in the root directory path are not allowed.
3. Click Yes to change the directory, or No to accept the default directory. If Yes, browse to the
appropriate directory, and then click OK.

Step 2: Optimize the initial blank

1. From the Tools menu, select Blank Opti, and then choose Blank Opti Setup.
The utility makes a comparison between the boundary of the formed part and the target
boundary to calculate the deviation. This deviation is applied to the initial blank and a new
boundary for the blank is created, as you see in the following image:

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 The zoomed area shows the deviation applied to the flat blank

Exercise 2: Blank Optimizer With Web Exclusions

This process is typically used to optimize the blank shape for progressive die forming where the blank
shape for optimization is considered excluding the webs connecting the continuous strip of blanks.
This exercise uses the model files:
Incremental_RADIOSS:
BlankOptiFinal.STA
BlankOptiInitial.nas
BlankOptimize_TargetLine_WebExclusion_Radioss.iges
Incremental_Dyna:
final-dynain
initial_dynain
BlankOptimize_TargetLine_WebExclusion.iges
Step 1: Optimize the initial blank

Before beginning, copy the files to a convenient working folder. This will be your new root directory.
Note: RADIOSS and LS-DYNA files should be kept in separate working folders.

1. From the Tools menu, select Blank Opti and then choose Select Root Directory.
2. Click Proceed.
A dialog opens for you to change the exiting location of the root directory to the directory where

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 your model files are stored. Note that spaces in the root directory path are not allowed.
3. Click Yes to change the directory, or No to accept the default directory. If Yes, browse to the
appropriate directory, and then click OK.

Step 2: Exclude web elements from the initial blank

1. From the Tools menu, select Blank Opti > Select Web Elements.
The flat blank loads into the session with the web selection options.
2. In the Enter no.of webs field, type 1.
3. Click proceed.
4. Click elements, and then select approximately half of the elements, as you see in the following
figure below.

Incremental RADIOSS selection Incremental LS-DYNA selection

5. Click proceed.
6. From the Tools menu, click Blank Opti > Blank Opti Setup.
7. In the file selection dialog, select the appropriate file:
For RADIOSS, select: BlankOptimize_TargetLine_WebExclusion_Radioss.iges
For LS-DYNA, select: BlankOptimize_TargetLine_WebExclusion.iges
8. Click Open. The deviation is applied to one half of the blank as opposed to the full blank. The
following figure shows the deviation compensated blank:

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HF-3110: HydroForming

Hydroforming is a metal forming process that involves using fluid pressure to shape the metal piece. It
begins with the metal piece to be formed being placed in a blank holder over the punch. The blank
holder and punch are then moved next to the fluid filled dome. Pressure inside the dome is increased to
form the part. As the punch moves against the diaphragm of the dome, the pressure inside the dome is
adjusted to form the part to the desired shape.
In this tutorial, you will learn how to set up of a tube hydroforming process.
This tutorial assumes that you are familiar with basic HyperForm functionality such as meshing and
mesh editing. If you need help on these topics, refer to the corresponding tutorials in the online help.
Files for Incremental_RADIOSS
tube_radioss.sta
hydro_die_geom_radioss.igs

RADIOSS Setup model

Files for Incremental_Dyna

tube_dynain
hydro_die_geom.igs

LS-DYNA Setup model

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Exercise: Basic Tube Hydroforming Analysis

Tools

This tutorial uses the following panels which are available in the Setup menu:
Sections panel
Materials panel
Components panel
Run Analysis panel

Step 1: Import the file

The model files are zipped in the tutorial location. Before proceeding, unzip the files.
1. Copy the file tube_radioss.sta from its location in the installation directory at \tutorials\mfs\hf
\incremental to the location where you intend to run this simulation after setup.

2. Click the Import Solver Deck icon . The Import tab opens with the options as shown below.
Make sure that the selection is per the figure:

3. Click the file browser icon and browse to find the file tube_radioss.sta or tube_dynain.
4. Click Open.
5. Click Import.

Note: During import of the sta/dynain file, only the node and
element definitions are read into HyperForm. The adaptive
constraints, initial stress, and initial strain quantities are
automatically placed into a new file called filename.sta.hmx/
dynain.hmx. This extra information should be automatically
included in the new setup by use of the #INCLUDE in the D00

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 0000.rad file for RADIOSS and *INCLUDE card for LS-DYNA.

Step 2: Rename the component

1. In the Model browser, expand the Component folder.

2. Right-click on the component 1 and select Rename.
3. Enter the new name as Tube and click ENTER.

Step 3: Create blank section properties

1. From the Setup menu, click Sections. The Section Definition panel is displayed.
2. In the section field, type tube_section.
3. In the thickness: field, type 1.3 (mm).
4. Click card image: and select the respective card image from the list:
For RADIOSS, select SH_ORTH
For LS-DYNA, select SectShll.
5. Click create.
6. Click return.

Step 4: Create tube material properties

1. From the Setup menu, click Materials. The Material Definition panel displays.
2. In the material: field, type CRDQ_steel.
3. Click card image:, and select the respective card image from the list:
For RADIOSS, select HillOrthotropic Tabulated
For LS-DYNA, select TransAnsioElasticPlastic.
4. Click import curve.
5. In the curve: field, type stress_strain_curve.
6. In the sigy = field, enter 185. (MPa)
7. In the k = field, enter 550. (MPa)
8. In the n = field, enter 0.21.

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9. Click create.
10.Click back.
11.Click create.
12.For LS-DYNA, click edit card and set Lankford coefficient (R) to 1.6.
13.Click return.

Step 5: Assign section and material properties for the tube component

1. From the Setup menu, click Components.

2. Double-click component: and select Tube.
3. Click section: and select tube_section.
4. Click material: and select CRDQ_steel.
5. Select a color.
6. Select the adaptive check box.
7. Click update.
8. Click return.

Note: By default, three levels of adaptivity are enabled. The

adaptive levels can be changed by using the Control Card
panel, and editing the parameter LevelMax in the card /
ADMESH/GLOBAL for RADIOSS and the parameter MAXLVL
in the Adaptive card for LS-DYNA. Refer to the RADIOSS/LS-
DYNA manual for more detailed information.

Step 6: Import the die geometry

1. Click on the Import Geometry icon . The Import tab opens.

2. Click the file browser icon and browse to find the file hydro_die_geom_radioss.igs/
hydro_die_geom.igs and double-click to open the file.
3. Click Import.
4. Click Close.

Step 7: Rename the upper and lower die components

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1. In the Model Browser, expand the Component folder.
2. Right-click on the component lvl1 and select Rename.
3. Enter the new name as upper_die and click ENTER.
4. Right-click on the component lvl2 and select Rename.
5. Enter the new name as lower_die and click ENTER.

Step 8: Display only the upper and lower die components

1. In the Model Browser, click the icons as shown in the figure below to turn on lower_die and
upper_die components.

Step 9: Set the current component to Upper_Die

1. In the Model Browser, under the Components folder, right-click on Upper Die and select Make
Current.

Note: This sets the current working component to be upper_die.

Step 10: Mesh the Upper_Die component using R-mesh

R-Mesh is a tool meshing utility available from the Mesh menu that allows you to specify several
parameters to create the mesh. The macro is intended for generating rigid tool meshes for
incremental analysis. For incremental analysis, the meshing parameters default settings are Minimum
Edge: 0.5, Maximum edge: 30.0, Chordal deviation: 0.1, and Fillet angle: 15.0.
The four parameters are defined as shown in the interface as shown below.

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1. From the Mesh menu, click R-Mesh.
The default parameters can be used here.
2. Select the Mesh to current component check box.
3. Click Mesh…
4. Select the yellow surfs button and select by collector.
5. Select the upper_die component and click proceed.
6. Click Close.

Step 11: Repeat Steps 9 and 10 using lower_die as the current component

1. Set the lower_die component as the default working component.

2. Mesh the lower_die surface using R-Mesh.

Step 12: Set up pressure loads using the Hydro Setup macro

1. Click Tools > Hydro > Hydro Setup.

2. A window pops up asking you to save the file. Type the file name as
tube_hydro_radioss_complete and specify the required location to save this file. The
HydroForming utility displays as below:

3. For Upper Die:, choose the upper_die component.

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4. Click Velocity: and type -2000. (mm/s)
5. Click Total travel: and type 8. (mm)
6. For Lower Die:, select the lower_die component.
7. For Tube:, select the Tube component.
8. For Adaptive levels:, change from the default of 3 to 1.
9. Click Coeff of friction: and type 0.125.
10.Click Initial pressure: and type 1000. (psi)
11.Click Final pressure: and type 6000. (psi)
12.Click Run to set up the hydroforming pressure loads.
Notice the pressure curve and velocity curve are set on screen.

Note: For RADIOSS, D00 and D01 files are created at this step.
Save the file as in Step 13 and directly use the RADIOSS
Manager to run these files. The RADIOSS Manager can be
accessed from Start > All Programs > Altair HyperWorks.

Do not execute the Run command either from the Utility

Menu or the main panel area.

Step 13: Save the analysis setup

1. Click File > Save As....

2. Enter the file name as tube_hydro_complete.hf.
3. Click Save.

Step 14: (Incremental_Dyna Only) Review the animation and run the analysis

1. Under Setup, click Run.

2. Click create dynain.
3. Click applied comps: comps and select Tube.
4. Click select.
5. Select the DYNA check box.
6. Click setup.
A message appears stating: "The entity set has been created."

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 Note: At the end of the computation, LS-DYNA will write out a file
named "dynain". This file contains all the stress and strain
information necessary to perform subsequent operations. This
file can be read directly by HyperForm and is essential for
performing multi-stage setups.

7. Click return.
8. Click dyna file and specify the name tube_hydro_complete.
9. Click run. A dyna input file tube_hydro_complete.bdf is generated. The file can be submitted to
LS-DYNA for solver analysis.

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HF-3120: Tube Bending

This tutorial shows you how to set up a simple tube bending analysis and assumes basic understanding
of the tube bending process.

Exercise: Basic Tube Bending Analysis

This exercise creates the model file and sets up a tube bending simulation from scratch. Standard
tooling geometries can be created from HyperForm and no preliminary file needs to be loaded to perform
this tutorial.

Tools

This utility can be accessed from the Tools menu under the Bend option, as shown below:

The following panels used in this tutorial can be accessed from the Setup menu:
Materials panel
Components panel
Run analysis panel

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Step 1: Create the tube bending model

1. From the Tools menu, select Bend and then select Model Creator. The following panel is
displayed.

2. Enter the values shown in the fields below:

Field Description Values

Tooling Parameters

Form Tool Center – X 0.0

Form Tool Center – Y 0.0

Form Tool Center – Z 0.0

Bend Die Radius (mm) 163

Offset From Center (mm) 100

Ball Parameters

Number of Balls 2

Ball Outer Dia (mm) 70.3

Tube Parameters

Outer Dia (mm) 76.2

Tube Length (mm) 750

Wall Thickness (mm) 2.6

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 Length Before First Bend 156.6
(mm)

3. Click Apply.
The graphical definition of all parameters is illustrated in the image below.

Note: Outer Dia = Tube diameter ( at mid surface of a tube) + Wall Thickness.

Step 2: Set up the bending simulation

For the Incremental_RADIOSS User Profile:

1. From the Tools menu, select Bend and then select Bend Setup. Type the file name as
tube_bending and specify the required location to save the file.
2. After saving, the bend setup utility appears:

Notice that some component selections are already done.

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3. Set the Number of Bends field to 3 to specify the number of bends.
4. Enter the following in the table to provide the bend sequence data:

Translate Rotate Bend Angle

156.2 0 56.2

87.2 -49.2 50.2

99.7 126.1 29.8

5. Click Run. The folder where you saved the file will have <filename>_0000.rad and
<filename>_0001.rad installed. The number of <filename>_000* files depends on the number of
bends in the Bending setup. In this case, it is 6 files – 0001.rad, 0002.rad, 0003.rad,
0004.rad, 0005.rad and 0006.rad files.
The tube bending problem has been set up completely.

Note: All tool parameters from the Bending Model Creator dialog are automatically applied
to the "Bending Setup". However, if you create the tube and tool meshes without using
the Bending Model Creator dialog, you will need to manually modify
[install_directory]\scripts\hyperform\hydroforming
\TubeBendingInitDefaults.dat to suit your needs.

For Incremental_Dyna user profile:

1.From the Tools menu, select Bend and then select Bend Setup. The following dialog appears:

2.Make the following component selections in the Hydro Tube Bending dialog by using the
selector for the corresponding fields.

Selector Label Component to Select

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 Form die: FormDie

Mandrel: Mandrel

Wiper die: WiperDie

Pressure die: PressureDie

Tube: Tube

Tube rigid control: CntrlRigid

Number of forming balls 2

Ball number 1: ball_1

Ball number 2: ball_2

Number of bends 3

3.Enter the following in the table for bend sequence data:

Translate Rotate Bend Angle

156.2 0 56.2

87.2 -49.2 50.2

99.7 126.1 29.8

4.Click Run.
The tube bending problem has been set up completely.

Note: All tool parameters from the Bending Model Creator dialog are automatically applied
to the "Bending Setup". However, if you create the tube and tool meshes without using
the Bending Model Creator dialog, you will need to manually modify
[install_directory]\scripts\hyperform\hydroforming
\TubeBendingInitDefaults.dat to suit your needs.

Step 3: Save the analysis setup

1. From the File menu, select Save As….

2. Use the file browser to save the file as tube_bending_complete.hf.
3. Click save.

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Step 4: Run the analysis

1. Run the analysis from the RADIOSS Manager. The RADIOSS Manager can be accessed from
Start > All Programs > Altair HyperWorks.

Note: Do not use the Run function from the Utility Menu or the
main panel area. This will rewrite the D00 and D0* files created
from the Bending setup.

2. Click run. An LS-DYNA input file named forming_complete.bdf is generated. The file can be
submitted to LS-DYNA for solver analysis (in the Incremental_LS-DYNA user profile).

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HF-3130: Blank Shape Predictor

The Blank development process for crash formed parts requires an initial guess based on die design
results. After you supply an initial guess, you run multiple iterations of forming simulations and visually
inspect the deviation of the simulated part boundary from the design CAD boundary.
To solve the blank-development problem, the blank shape predictor tool in HyperForm tracks the
boundaries of the CAD design boundary from the simulated part onto the initial blank. A resulting
traced line on the initial blank can be used to run a second simulation, the part boundary of which will
be closer to the design CAD boundary. Generally the Blank Predictor tool reaches the required blank
shape after three to four simulation iterations. Using a rectangular blank for the first of these simulation
events can minimize the number of iterations required to reach the desired blank shape. Note that you
can also use HyperForm's Line Tracing feature to trace the design CAD boundary in multiple stages.

Exercise 1: Using the HyperForm Blank Predictor

Step 1: Specify Files for the Blank Shape Predictor

1. Launch HyperForm with the Incremental_Radioss user profile.

2. Select Tools > Blank Shape Predictor.

3. In the Blank STA/dynain file field, navigate to the file, Form.sta, and then click Import. The
.sta file is generated after the first forming simulation with the rectangular blank.
4. In the Target line field, navigate to the file, Design_CAD_Boundary.iges, and then click
Import.
5. Click the Predict tab, and move your cursor to the field for Stage1. The cursor changes to a
plus symbol, as shown in the image in step 7. below.
6. In the Result file column for Stage1, click, and then navigate to the file,
Line_Trace_Result_file.h3d, which is generated from the first iteration of the forming
simulation.
7. Next to Select part, click the yellow Components button twice, and then click an element on
the model in the graphics area.

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8. Click proceed.
9. Next to Select Target lines(s), click the Lines button twice, and then click lines >>
displayed.
10.Click proceed >> Predict. HyperView opens in batch mode, and displays the predicted blank
shape.
The following image shows you an overlay of the .sta file elements in transparent mode, the
design CAD boundary, and the predicted blank shape:

Step 2: Trim the Predicted Shape from the Rectangular Blank

1. From the File menu, select Import > Model.

2. From the Import tab, navigate to Form_Dev_Blank.hf and click Import. This file loads on top
of the existing .sta file and predicted blank outline.
3. In the Model browser, turn off the display of the surface and elements for all the components
except for Blank 1 and Predicted_line.

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4. From the Geometry menu, select Edit > Surfaces > Trim with Lines. On the panel that
appears, set the options as you see outlined in red in the following image:

5. Under the with lines header, click surfs, and then pick the blank surface from the screen.
6. Under the with lines header, click lines, and then select the predicted blank outline from the
screen.
7. Click trim.
8. After the trim operation, you can cut the required shape from the rectangular blank using the
Delete panel. To open the Delete panel, press F2.
9. From the Delete panel, click the extended entity selector and change the selection to elems.

10.Click Elems >> By Geom >> Surfs, and then pick the rectangular surface from the screen.
11.Click add to selection and then click delete entity. The following figure shows you the new
blank shape cut from the rectangular blank:

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 12.Use the new shape and follow HF-3002. Set up a new a forming simulation and compare the
simulated shape with the design CAD boundary. Repeat Exercise 1. to predict the new shape
until the simulated part shape matches with the design CAD boundary.

Exercise 2 (Optional): Trace Design CAD Boundary from HyperView

Step 1: Open HyperView from HyperForm and Load the HyperForm Profile

The model files for this exercise are zipped in the directory where your HyperForm tutorials are
installed. Before proceeding, copy and unzip the files into a working directory.
1. Launch HyperView.
Note: In any HyperForm user profile you can access HyperView from the toolbar by selecting
Applications > HyperView.
2. In HyperView, select File > Load > Preference File. The Preference file window opens.
3. Select HyperForm Utilities, and then click Load. From this point on, HyperForm appears on
the HyperView toolbar.
4. Select File > Open > Model. The Load model and results panel appears below the graphics
screen:

5. For Load model, navigate to your working directory, and then select the file, Form A001. Notice
that the Load results field gets populated with the same path as Load model.
6. Click Apply. The results file loads and the forming simulation of the b-pillar is displayed.
7. From the Model browser, turn off the tools, and from the animation controls, proceed to the last
time step. The part shape, the output from the rectangular shaped blank, is displayed as you
see in the following image:

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Step 2: Trace the Design CAD boundary and export the new blank shape

1. From the toolbar, select HyperForm > Import and Trace Line. The Import Line window opens.
2. Navigate to the file, Design_CAD_boundary.iges. The Line Trace panel opens at the bottom of
the screen.
3. With the Components button highlighted, click the part shape from the screen. Notice that the
name of the blank as seen on the Model browser appears at the center of the part shape
confirming your selection.
4. Click Create. Notice the trace of the line from the final shape to the initial blank shape is
automatically displayed on the screen. The trace is shown for every time step by default. If you
don’t see the trace for every time step, then animate once by clicking play from the animation
controls toolbar.

5. On the animation controls toolbar, click to see the shape of the trace on the initial blank
(time zero).

By default, the design CAD boundary appears in pink, and the trace of the design CAD boundary
at every time step appears in gray.

6. To export the traced shape, from the Display Options on the bottom-right corner of the screen,
click Export.

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 The pink line is the design CAD boundary and the gray line is the trace of the design CAD
boundary at time zero.

7. Rerun the forming simulation using the traced shape and compare the results with the design
CAD boundary. If the two boundaries do not match, then repeat the trace and rerun the forming
simulation with the new blank shape.

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Optimization Tutorials

HF-4010: Mesh Morphing

HF-4020: Optimization 1-Step
HF-4040: Process and Shape Optimization Using RADIOSS Incremental

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HF-4010: Mesh Morphing

The HyperMorph module helps you alter models in useful, logical, and intuitive ways while keeping mesh
distortion to a minimum. With the module, you can:
Make smooth changes to die geometry parameters like the draw wall angle.
Use the morph volume feature to create a volume around a group of elements, which allows you to
morph to the desired shape by dragging the handles at the corners of the volume.
This tutorial assumes that you are familiar with HyperForm functionalities and the HyperMorph module.
Information on HyperMorph topics can be found in the online help.

Exercise: Morphing the die using HyperMorph

This exercise uses the model file form_tutorial.hf.

Tools

This tutorial uses the HyperMorph module, which can be found in the Tools menu.

Step 1: Load the user profile

1. On the Preferences menu, click User Profiles.

2. For Application, select Manufacturing Solutions. Verify that HyperForm and RADIOSS One
Step are selected.
3. Click OK.
4. Click return.

Step 2: Load the file

1. From the File menu, click Open.

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2. Browse to the file <installation_directory>\tutorials\mfs\hf\1step\form_tutorial.hf.
3. Click Open.

Step 3: Create the morph volumes

Morph volumes within the HyperMorph module allows you to enclose a given mesh with morph
volumes, alter the morph volumes to fit your model, and then change the shape of your model by
modifying the morph volumes.
1. From the Applications menu, select HyperMorph.
2. Select the morph volumes button on the main menu.
3. Select the create subpanel.
4. Use the switch to select create matrix.
5. Enter the following values:
X density = 2
Y density = 10
Z density = 1
buffer % = 5
6. Uncheck auto-tangent. Keep all the other settings as they are.
7. Click elems and select displayed.
8. Click create.
The entire part is enclosed in twenty hexagonal morph volumes. These twenty morph volumes are
the result of 2 x 10 x 1 input for X, Y and Z in the create matrix as shown in the figure below. Red
color handles are created at the end corners of each of the twenty boxes.

8. Select the split/combine subpanel.

9. Ensure that the selection of the left top toggle is split mvols.
10.Keep all the other settings as default except uncheck the box for make tangent.

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11.Pick the edge close to the black X as shown in the figure below and type in 0.62 in the box for
single split.

12.Click split.
As a result of this split, ten more morph volumes will be created. The split is propagated to the
other end. Red color handles are created at the corners of the morph volumes.

13.Click return to exit from the Morph Volumes panel.

Step 4: Morphing the die

1. From the main menu, select Morph.

2. From the header bar, select the user view icon .

3. Click rear to change to rear view.
4. Select the move handles subpanel.
5. Make sure the top selector is set to translate mode.
6. Make sure the middle selector is set to along xyz.
7. Use the following values:
X=0
Y = -20
Z=0

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8. Click handles.
9. Click handle again and select by window from the popup window.
10.With the points button activated, draw a window, as shown in the image below.

Handles selected by window option

11.Click select entities.

12.Click select again to go back to the Morph panel.
13.Click morph. The die after morphing is shown below.

Step 5: Record the morphed shape sh1

1. Select the save shape subpanel.

2. For name =, type sh1.
3. Toggle the as handle perturbations selection to as node perturbation.
4. Click save.
5. Click yes to the message window "Save perturbations for node at global and morph volume
handles? (y/n)".
6. Click undo. This will recover the model back to original model shape.

Step 6: Morph the second shape

1. Select the move handles subpanel.

2. Use the values:
X=0
Y = 20
Z=0

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3. Click handles.
4. Click handles again and select by window from the popup window.
5. With the points button activated, draw a window, as shown in the image below.

Handles selected by window option

6. Click select entities.

7. Click select to go back to the Morph panel.
8. Click morph. The die after morphing is shown below.

Step 7: Record the morphed shape sh2

1. Select the save shape subpanel.

2. For name =, type sh2.
3. Verify the toggle is set to as node perturbation.
4. Click save.
5. Click yes.
6. Click undo.

Step 8: Morph the third shape

1. From the tool bar, click on the user view icon .

2. Click the left view from the pop up window.
3. Select the move handles subpanel.
4. Use the values:
X = -20

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 Y=0
Z=0
5. Click handles. You are now in entity selection mode.
6. Click handles again and select by window from the popup window.
7. With the points activated, draw a window, as shown in the image below.

8. Click select entities.

9. Click select to go back to the Morph panel.
10.Click morph. The die after morphing is shown below.

Step 9: Record the morphed shape sh3

1. Select the save shape subpanel.

2. For name =, type sh3.
3. Verify the toggle is set to as node perturbation.
4. Click save.
5. Click yes.
6. Click undo.

Step 10: Apply all saved shapes

1. Go to the apply shapes subpanel.

2. Click shapes and select the three saved shapes.
3. Click select.
4. For multiplier, keep the default value, 1.0.

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5. Click apply.
All the three shapes are applied together.
6. Click on the save shape subpanel and enter the name as combine for the combined shapes.
7. Click save.
8. Rotate the model to see the results.
The resultant shape change of the part is shown in the figures below.

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HF-4020: Optimization Using RADIOSS One Step

This tutorial guides you through the setup of an optimization study using the link between HyperForm
and HyperStudy. This tutorial assumes you have familiarity with HyperForm, HyperMorph, HyperStudy,
and basic understanding of optimization.
Stamping processes typically deal with a large number of shape and process design variables. In order
to automate the process of arriving at an optimal choice of design variables, a link between the analysis
program and the optimization program is essential. For the example problem in this tutorial, you set up
process variables using Hyperform panels, and shape variables using HyperMorph, a mesh morphing
tool. To run the analysis, you use RADIOSS One Step.
You can easily extend this method to set up an optimization study with incremental analysis.
Problem Overview
A quality function that minimizes failure by tearing or wrinkling has been developed using the major and
minor strain ratios that correspond to the formability zones under a forming limit diagram. The objective
function is to minimize the distance between the major and minor strain coordinates for each material
point in strain space and the curve describing the quality function as illustrated in the following figure:

Quality Function for Minimizing Formability Defects

The shape variables are the blank edge profile. The die entry radius, the part depth, and the process
variables are the blankholder force and the drawbead restraining forces as illustrated in the following
figure:

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Distribution of Design Variables

Step 1: Load the HyperForm One-Step Environment File

1. On the Preferences menu, click User Profiles.

2. For Application, select Manufacturing Solutions. Verify that HyperForm and
RADIOSS_One_Step are selected as below, and then click OK.

Step 2: Load the HyperForm Model File

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1. From the File menu, click Open.
2. Navigate to the file: <installation_directory>\tutorials\mfs\hf\Opti\part1b_opti.hf, and
then click Open.

Step 3: Set Up and Run the Optimization Study

1. From the OneStep tab, check that the part has an assigned material, thickness, blank holder
and drawbead as you see below:

2. From Settings, right-click Optimization, and then select On:

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3. Navigate to your Base Directory (working folder). From Settings, right-click Base Directory,
and then select Set:

4. From the Browse For Folder dialog that appears, navigate to the correct folder, and then click
OK.

5. Return to the OneStep tab and check that the options are set as below. To change a setting,
right-click the option.

6. On the OneStep tab, locate the Design Variables branch which contains the shapes and process
variables in the model, and then do the following:
From Blankholders, right-click bh.friction, and then select Remove.
Under bh.tonnage, left-click Upper bound, and then click the value next to it and enter 200.
Under bh.tonnage, left-click Lower bound, and then click the value next to it and enter 0.
7. From Drawbeads:
Under db1.restraintforce, left-click Upper bound, and then click the value next to it and
enter 200.

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 Under db1.restraintforce, left-click Lower Bound, and then click the value next to it and
enter 0.
Repeat these two bullet steps for db2.restraintforce and db3.restraintforce.
8. From Thickness, right-click part.thickness, and then select Remove.
9. From Friction, right-click part.friction, and then select Remove.
10.To animate a shape variable, right-click the variable, and then select Animate:

Alternatively, click the Animate button on the bottom, right of the screen.
Click Close to close the animate panel.
11.To run the optimization study, on the OneStep tab, move your cursor to the white space near the
scroll bar, right-click, and then select Run:

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 Note: Your cursor needs to be close to the scroll bar for the Run command to appear.

Step 4: View the Results of the Optimization Study

1. After the optimization converges, HyperView opens with the results of the optimized shape.
If the optimization does not converge, then an optimization summary dialog appears with a
prompt for you to open the closest results.
Follow the prompt. A screen appears with something like the following:

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Step 5: Publish Report

1. Switch to the HyperForm Radioss OneStep window.

2. From the Optimization tab, right-click in the white space near the scroll bar, and then select
Publish Report.
3. The default web browser opens with the results of the actual part before optimization, followed by
the results of the five most optimum designs of the part after optimization.

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HF-4040: Process and Shape Optimization Using Incremental RADIOSS

This tutorial guides you through the setup of an optimization study using the link between HyperForm
and HyperStudy. Familiarity with HyperForm, HyperMorph and HyperStudy is required. This tutorial also
assumes that you understand the basic principles of optimization.
Stamping processes typically deal with a large number of shape and process design variables. In order
to automate the process of arriving at an optimal choice of design variables, a link between the analysis
program and the optimization program is essential. For this project, you set up process variables in
HyperForm panels and shape variables in HyperMorph, a mesh morphing tool. To run the analysis for
this project, you use HyperForm’s RADIOSS Incremental solver.
Problem Overview
A quality function that minimizes failure by tearing or wrinkling has been developed using the major and
minor strain ratios that correspond to the formability zones under a forming limit diagram. The objective
function is to minimize the distance between the major and minor strain coordinates for each material
point in strain space and the curve describing the quality function as the following diagram illustrates:

Quality Function for Minimizing Formability Defects

The Blank Edge profile is considered to be a shape variable as in the following figure:

Actual Blank Shape Variables Considered for the Blank

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Step 1: Load the HyperForm Incremental User Profile

1. On the Preferences menu, click User Profiles.

2. For Application, select Manufacturing Solutions. Verify that HyperForm and
Incremental_RADIOSS are selected, and then click OK.

Step 2: Load the HyperForm Model File

1. From the File menu, click Open.

2. Navigate to the file: <installation_directory>\tutorials\mfs\hf\Opti\Form_opti.hf, and then
click Open. The following model is displayed:

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Step 3: Set Up and Run the Optimization Study

1. Set up the model in the User Process utility as described in the tutorial, HF-3002.
2. To change the setting of an option, right-click the option, and then select a setting. Change the
options as needed in the following steps.
3. Right-click Optimization Object, and then select On. Notice that the Optimization tab opens next
to the User Process tab, and captures all of the necessary model information required to set up an
optimization study.
4. Specify a working directory for your study. From the Optimization tab, under Settings, right-
click Base Directory, select Set, and then specify a directory in the dialog that appears.
5. Under Settings, right-click Type, and then select Part geometry and process parameter.
6. Under Settings, right-click Scope, and then select Full Part.
7. Right-click Objective, and then select Minimize distance to function.
8. Right-click Constraints, select Thinning, select Less than %, and then enter 25.
9. Under Constraints, right-click Number of iterations, and then enter 25.
10.From Design Variables, right-click Tool Loads, and then select Remove.
11.From Design Variables, right-click Thickness, and then select Remove.
12.From Design Variables, right-click Friction, and then select Remove.
13.To animate a shape, from Design Variables, right-click a shape, and then select Animate, as you
see in the following image. The Animate panel opens below the graphics.
Note: Only the Blank shape is considered for this study.

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 Alternatively, click the Animate button on the bottom, right-side of the screen.
Click Close to close the Animation panel.
14.To run the optimization study, right-click in the white space towards the scroll bar, and then
select Run.
Note: Your cursor needs to be close to the scroll bar for the run command to appear.

Step 4: View the Results of the Optimization Study

1. After the optimization converges, HyperView opens with the results of the optimized shape. The
following shows a comparison of results before and after optimization:

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 Before Optimization After Optimization

Step 5: Publish Report

1. From the Optimization tab, right-click in the white space near the scroll bar, and then select
Publish Report.
2. The default web browser opens with the results of the optimization.

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Result Mapping Tutorials

HF-5000: Using Results Mapper in HyperCrash

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HF-5000: Using Result Mapper in HyperCrash

In this tutorial, you will learn the procedure for mapping forming results onto structural models using
the HyperWorks Results Mapper.
In real time practice, you may come across situation where the end results of formed parts have to be
considered when it goes as a part of an assembly for structural analysis to depict a more realistic
situation. To achieve this, HyperWorks Results Mapper is used.
HyperWorks Results Mapper (HWRM) is a HyperCrash based tool that provides a framework to initialize a
structural model with results from a forming simulation. You will go through a simple procedure loading
the structural model and forming simulation results followed by mapping the results and finally
exporting the mapped data in a structural solver format. For output, the structural solvers currently
supported are RADIOSS Y, RADIOSS STA, Abaqus and OptiStruct. The results are transformed as
necessary if the forming and structural models are in different co-ordinate frames.
In this tutorial, you will first import the structural model and find a region on it which is almost similar
to a region on the formed component. This region identification is the reference for the Results Mapper.
Then, you will import the results of the formed component, identify the same region, and map the
forming results to the structural model.
This tutorial assumes that you are familiar with HyperCrash. If you need help on these topics, please
refer to the corresponding tutorials in the online help.
Results Mapper can be accessed by clicking Start > Altair HyperWorks > Manufacturing Solutions
> Results Mapper.

Exercise: Mapping the forming data from a STA file onto a RADIOSS mesh

This exercise uses the models:

EndOfFormingResults.sta
MeshToBeMapped_0000.rad
MeshToBeMapped_0001.rad

Step 1: Load the structural model into HyperCrash

1. Click Start > Altair HyperWorks > Manufacturing Solutions > Results Mapper.
2. In HyperCrash, click on File, then click Import and select RADIOSS, as shown in the figure
below.

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3. Browse and locate the file MeshToBeMapped_0000.rad. Click OK to open the file.

4. The Import Choice for Units dialog is displayed. Click on Ignore and Import.

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5. Click on Process and then select Results Mapper from the menu, as shown below.

This will bring up Results Mapper inside HyperCrash as shown below.

Step 2: Load the STA file into HyperCrash

1. Click on the Load Stamping File icon inside the Result Mapper.
2. Click on RADIOSS and browse and locate the file EndOfFormingResults.sta.
3. Click on the file and click OK to bring the file into the session.
4. Click on the model name as shown in the red box below to highlight it and click on the glasses
icon to display the model in the small screen.

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Step 3: Position the STA file to align it with the target model

Upon loading the files, the STA file, which is in the forming coordinate system, and the target model,
which is in the car coordinate system, appear on top of each other, as shown below:

1. Click on the Positioning button.

2. Click on the third option, as shown in the red box below:

3. Click on the arrow next to node Id below the header First couple of nodes.
4. Pick the first node on the horizontal model shown on the left hand side of the image below.

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5. Rotate the model by ~90 degrees (press and hold the Ctrl button and left mouse button, move the
mouse to rotate) to make the second selection as shown on the right hand side of the image
above.
6. Follow steps 4 and 5 to select 2 more corner node pairs as the second couple of nodes and the
third couple of nodes. Refer to the image below:

7. Click on Optimize.
8. Click on Allow Rotation.
9. Click on Apply move.
10.Click on Ok in the bottom left hand corner to validate and accept the positioning.

Step 4: Map the results from STA mesh to structural mesh

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1. Click on the include picked part icon .

2. Graphically select the structural model from the screen. The selected part name is displayed within
the Results Mapper in the right hand column.
3. Click Yes on the right hand bottom corner of the screen.
4. Click on Map Results at the bottom of the Result Mapper. The results are mapped and are shown
in the Results Mapper area.

Step 5: Change result type and export mapped mesh

1. Click on the Contour tab.

At this point, you may need to expand the Results Mapper tab by dragging the right side bar
further out. This will enable you to see the entire Contour tab of the Results Mapper.

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2. In the Type of Value: field, select Plastic Strain from the drop down menu.
Notice that the mapped data changes to Plastic Stain both for STA mesh and the structural mesh.
3. Use the arrows in the On integration point: field to change the value in the box. Notice that the
mapped result type is automatically updated with the new data.
4. Click on the Output tab.
5. Click on the Browse button.
6. Navigate and select the destination folder.
7. Type PlasticStrain.inp in the field and click on OK.
8. In the File Format field, select Abaqus.

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9. Make sure the Thickness, Plastic Strain and Stress Tensor fields are checked.
10.Click on Export. The file is exported.

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HF-5100: Result Mapping Using Process Manager

In this tutorial, you will learn the procedure for mapping forming results onto structural models using
the HyperWorks Results Mapper.
In real time practice, you may come across situation where the end results of formed parts have to be
considered when it goes as a part of an assembly for structural analysis to depict a more realistic
situation. To achieve this, HyperWorks Results Mapper is used.
HyperWorks Results Mapper (HWRM) is a Process Manager-based tool that provides a framework to
initialize a structural model with results from a forming simulation. A Process Manager template takes
you through a step-by-step approach starting from loading the structural model and forming simulation
results into Fepre and HyperView respectively, followed by choosing the data to map and finally
exporting the mapped data in a structural solver format. Any scalar, vector or tensor data that can be
read into HyperView can be chosen for mapping. For output, the structural solvers currently supported
are OptiStruct, Nastran, LS-DYNA and Abaqus. The results are transformed as necessary if the forming
and structural models are in different co-ordinate frames. Some amount of geometric difference between
the forming and structural model is tolerated.
In this tutorial, you will first import the structural model and find a region on it which is almost similar
to a region on the formed component. This region identification is the reference for the Results Mapper.
Then, you will import the results of the formed component, identify the same region, and map the
forming results to the structural model.
This tutorial assumes that you are familiar with HyperView. If you need help on these topics, please
refer to the corresponding tutorials in the online help.

Note: Starting version 11.0, HyperWorks Results Mapper is in

maintenance mode. Results Mapping Using HyperCrash is
recommended as a general purpose mapping tool.

Exercise: Mapping Forming Analysis Results onto Structural Models

This exercise uses the model files mapping.hf.

Tools

To do results mapping using the Process Manager, first launch HyperView and then load the Process
Manager template file. Once the template file is loaded, the tutorial can be completed.

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Step 1: Launch HyperView and load the template

1. Launch HyperView by clicking Start > Programs > Altair HyperWorks > HyperView.
2. Click View > Browsers > HyperWorks > Process Manager.
3. Click in the Load template: field and select Browse...
4. Load the template file from the following location: \hm\scripts\hyperform\pm\hwrm
5. Click Open.
6. In the Create/Open Process Instance dialog, enter a name and location in the appropriate fields
to create a new instance.

7. Click Create/Open.

Step 2: Load the structural model

1. In the Type: field, select HM/HF (the structural file format).

2. Click Browse… next to the File name: field and browse to the file <installation_directory>
\tutorials\mfs\hf\ResultMapping\mapping.hf.
3. Click Import. The application automatically switches to HyperMesh and the User Profile dialog
opens. Accept the default user profile and click OK.
Notice the structure file is imported into the Process Manager tab. The first step is checked with
a green mark indicating its completion.

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Step 3: Select the structural part and its orientation for mapping

1. Make sure the Components button is active. Click on Components and graphically select any
element from the displayed component to be mapped.

2. Click the top view icon to change to top view.

3. Click the node list button and select three nodes and a base node on a region of the selected
component so that the same region can be identified on the component from forming analysis. The
image below shows the location of the nodes on the structural model.

4. Click Apply.
Notice the second step is checked on the Process Manager tab.

Step 4: Load the forming results model

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1. In the tutorial folder, unzip HWRM_forming_result.zip. All the D3PLOTXX files form analysis
results previously created by LS-DYNA into the same folder.
2. For both the Model file name: and Result file name: fields, click Browse… and select the
d3plot file from the forming simulation, as shown in the image below.

3. Click Import.

Note: The operation opens a second window in HyperWorks

Desktop. The window on the left (HyperMesh) contains the
structural model and the right window (HyperView) contains
the formed component.

Step 5: Display the formed part

For this set of steps, make sure the HyperView window is the active window. With the blue halo
surrounding the forming result window (right window), by the following:
1. Click on the Results tab to open the Results Browser.

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2. Expand the Components folder. Right-click on Shell 2 and select Isolate to turn off the display
of all components except the blank (or the formed component).

3. Click on the Shaded Elements and Mesh Line icon to turn on the mesh for the displayed
component.
4. Click the top view icon to change to top view.
Notice the structure and forming mesh are different as shown in the image below.

Step 6: Select mapping parameters on the formed part

1. With the yellow Components button highlighted as shown below, click on the formed part on the
graphics area to highlight it.

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2. Make sure that the N1 N2 N3 option is selected in the Aligning plane: field. If another option is
selected, click the toggle switch and select N1, N2, N3 option from the pull down menu, as shown
below:

3. Highlight the displayed formed component by clicking on it once. With N1 highlighted, click on the
nodes of the formed component in an order as shown in the image below. Notice that this region
corresponds approximately to the same nodes of the structural part.

4. From the Mapping Parameters pull-down list, select the parameter that needs to be mapped,
such as thickness, strain, etc. For this exercise, select Thickness.
5. Verify that both Model scaling and Result scaling are set to 1.0.
6. Click Apply.

Step 7: Map and export data

1. From the Template: pull-down list select the format for export (example: RADIOSS, Nastran, LS-
DYNA and Abaqus) as shown below. In this exercise, select LS-Dyna.

2. Click the Browse… button next to the File name field and specify the name result.dat for
exporting.

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3. Click Save.
4. Click Exec.
A new animation window opens displaying the contours of the mapped result on the structural
model.

5. Open the result.dat file using any ASCII text editor. Notice thickness results are mapped as
nodal thickness. This result.dat file can also be included in the model file for further analysis.

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HF-6000: Die Structure Optimization

The Die Structure Optimization process is a function used to automatically transfer tool contact forces
from stamping analysis to a structural model and an easy step-by-step setup of die structure
optimization model. The Die Structure Optimization process consists of two steps:
Die Stress Analysis
Die Optimization

Exercise 1: Set up and Run Die Stress Analysis

This exercise uses the model file DieStress.hf

Tools

Die Stress Analysis and Die Optimization features are under the Tools menu.

Step 1: Launch Die Stress Analysis

1. On the toolbar, select File > Open and browse to the file <installation_directory>\tutorials
\mfs\hf\Opti\DieStress.hf.
2. From the toolbar, select Tools > Die Stress Analysis.
The Create/Open Process Instance appears:

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3. For Folder, click and indicate a directory to save the results of the analysis.
4. Click Create/Open.
The Process Manager tab appears in the tab area. The Process Manager is a step by step
approach to preparing and running Die Stress Analysis.

Step 2: Setup Die Stress Analysis

1. In the panel area, Steel is shown as the default material in the Material field. Click Apply.
Notice that the white check mark turns green for Tool Material in the Process Manager tab.

Note: Clicking on Apply at each step will turn the white check
mark green in the Process Manager and a white check
appears for the next option.

2. For the Result file field, select either RADIOSS or LS-Dyna as the stamping solver.
3. Click on Browse… and locate and load the results of the forming analysis. In this exercise you
will use the file LawnMower2A001.
4. Click Apply. The Process Manager launches HyperView to query the model and create a list of
components that are available in the stamping model. Once the results are brought back into
HyperForm, you will be able to select which tool to extract the contact forces from.
5. For the Result part field, select Punch and click Apply. This is the tool from which forces are
extracted at the last step of forming analysis. This will launch HyperView for a moment and will
close on itself.
6. Click on Components: and select the skin of the Die component from the screen. This will be the
part onto which the loads will be mapped.
7. Click proceed.
8. Click Apply.

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Step 3: Display Only the Punch Component

1. In the Model Browser, click on the plus symbol next to LoadCollector to expand the tree.
2. Turn off the loads display by clicking on the mesh icon next to operational.
3. Expand the Components folder, and click on the mesh icon to display the Punch_solid
component.

Step 4: Define Holding and Lifting Points on the Structural Model

1. Click on the Process Manager tab.

2. Click on Nodes twice and select By Sets.
3. Select the Holding component. Notice that the bolt location nodes of the die are highlighted on
the screen.
4. Click select.
5. Click proceed.
6. Click Apply.
7. Click on Nodes twice and select Lift. Notice the set of nodes on the die gets highlighted on the
screen.
8. Click select.
9. Click proceed.
10.Click Apply.
11.Enter 1500 in the lifting height: field.
12.Click on Apply. This will create rigid elements connecting the nodes selected on the lifting location
of the punch to the CG of the model, as shown below.

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 13.Click on Apply.
14.Click on Browse and select a location to save the file. Enter the name with a .FEM as the
extension.
15.Click on save.
16.Click on Export to produce the input file.
17.Click on Export&Run to produce the input file and run stress analysis.

Note:
Make sure that all the steps on the Process Manager tree has
a green tick mark which indicates that all the steps were
successfully completed.
Stress analysis on the punch is done in the background. The
results of the stress analysis will be the input for Die Structure
Optimization.

Exercise 2: Set Up and Run Die Structure Optimization

Die Optimization can be accessed from the Applications menu.

Step 1: Setup the Model for Optimization

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1. Select the Design component under Status column, as shown in the figure below:

2. Click on Apply.
3. Enter 25.0 in the Min Member Size: field.
4. In the Draw Direction: list, select Z.
5. Click on Apply.
6. In the Volume Fraction: field, enter 0.3.
7. Click on Apply.
8. For Objective:, select Max Stiffness.
9. Click on Apply.
10.Next to the Export File: field, click on Browse and enter a file name with the extension .fem.
11.Click on Save.
12.Click on Export to create the input file for optimization.
13.Click on Export&Run to create the input file and run the optimization.

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HF-0010: Introduction to HyperBlank Macros

HyperBlank Process Macros

This is the interface for HyperBlank with the OneStep tab active. This is the default setting when
HyperBlank is started. The various macros that are available for HyperBlank are available on the Utility
Menu, which is also on the left side of the interface. See the HyperBlank online help for information
about the specific macros that are available.

HyperBlank interface with the OneStep tab active

All the macros are located on the Utility Menu. These macros allow you to quickly set up an analysis for
one step simulation. The macros are divided into the following three sections.

Model Allows you to import, cleanup, and mesh the model.

Setup Allows you to setup the model for simulation.

Resul Allows you to do post-processing once the analysis is done.

ts

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HyperBlank Utility Menu

Further explanation of each application type is provided in the subsequent tutorials.

Return to HyperForm Tutorials

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