eta/DYNAFORM 5.9.2.1 Die Simulation Training Manual
Contents
1. Seam gt EE ar a HIRED REA IT CI Select by Part Filter Filter Type Allin Region Boundary ti EE cua Besse E 5 The Upper Tool is defined Click Exit to exit Define Tool NN a a 2 EM AD To define the Binder 1 Click the Binder button and then select the Select Part button from the Define Tool dialog window 2 Click Add Elements from the Define Tool window 14 eta DYNAFORM Training Manual DIE SIMULATION SETUP inder efine Bi D t e The elements on binder surface are g amp un gt q INNEEHEERES LLL DLL ve CTI T Py 5 gt O O amp 5 un D 3 o 4 2 5 5 UL 77 LL Sd B 5 e 5 e T 9 di m 229 E 2 ao H aL g ajl r g Ia T en L E 15 Manual ining eta DYNAFORM Tra DIE SIMULATION SETUP 4 The Binder is defined Click Exit to exit Define Tool XH HEHHE H j te2. 22 24 27 POST PROCESSING witheta POS D 30 I Reading the Results File into the Post 4 10100200200000000000000000000000000000000004 30 Anann e a M 32 USE 33 IV Check theformins Resultof FLD 34 V Check the forming Result of 34 eta DYNAFORM Training Manual 1 INTRODUCTION INTRODUCTION Welcome to the eta DYNAFORM 5 9 2 1 Die Simulation Training Manual The eta DYNAFORM is the unified version of the DYNAFORM PC and UNIX platforms This manual details a step by step quick Simulation process through the Die Simulation interface process Users should take the time to learn these setup processes as 1 15 different from the traditional setup process such as AutoSetup In Die Simulation use INCSolver to do the sheet metal quick simulation analysis INCSolver is a nonlinear transient dynamic finite element program using explicit scheme to solve equations of motion commonly referenced as incremental code or explicit code INCSolver uses the SMP Shared Memory Processing computing scheme to take full advantage of multiple CPU multiple core and multiple thread configurations of latest c
3. E tt aut LII LIT E Pee ee ey m e 7 Set force percentage for each bead The force percentages of all drawbeads is in the following table 26 eta DYNAFORM Training Manual DIE SIMULATION SETUP 5 23 ow 9 25 0 0 25 0 fine 4 22 0 H 1 12 25 0 20 33 0 3 33 0 25 0 25 0 e 0 25 0 c 33 0 5 0 0 8 Click Exit to exit the Drawbead dialog box The followings are the description of other functions in the Die Simulation interface VII Lance and Trim allows the user to define Lancing and Trimming stages Advanced allows the user to change default parameters related to Die Simulation Help brings some tips for the user about the Die Simulation Submit Job brings the user to the analysis menu Exit will allow the user to exit the Die Simulation menu Submit Job After verifying the tool motion is correct we can define the final parameters and run the analysis l eta DYNAFORM Training Manual Click the Submit Job button to display the Submit Job dialogue window shown below 2 DIE SIMULATION SETUP Die Simulation Die Simulation tion Draw Type Single action Inverted draw Upper Tool Available Upper Tool Blank Parameters Material Thickness BH180 0 80 ER NUUS Binder Close Velocity 2000 00 I Lower Binder Force
4. 1334000 00 Spring Back Lower Binder Travel les 00 Adaptive Level 4 ww Lance 0 Trim 0 Advanced Help CPU Multi w Unda Preview Submit Job Report Exit submit Close 2 Toggle on Gravity Load to perform gravity loading analysis prior to Drawing analysis 3 Setthe Adaptive level to 4 and Select Multi from the CPU type button as shown below Submit Job Spring Back Adaptive Level 4 ww CPU Multi ww Submit Close 4 Click the Submit button to run the job 28 eta DYNAFORM Training Manual DIE SIMULATION SETUP Pid Job Submitter 2014 R1 ioj Solver amp LS DYNA S D Program Files ETA Dynaform 5 9 24sdyna exe LS DYNA Control Parameter LS DYNA D D Program Files ETA Dynaform 5 9 24sdyna d exe Memory 500 MB Iv Auto UTILITYBATCH D Program Files ETA Dynaform 5 9 2 UtilityBatch exe No of CPUs 88 MSTEP D Program Files ETA Dynaform 5 9 2 MStep exe Pause between Jobs D Sec INCSolver D Program Files ETA Dynaform 5 9 24DEMS SC EXE Not use MPP In Folder Soler MStages Memory Status Message Summary Force Die Simulationfin E DF592_TestFiles Application_M Other Param 4 Group1 MPP Submit Jobs Command FASTAMP320NO 328757879 D Program Files ETA Dynaform 5 9 2 592 TestFilesvApplication ManuahDie Sim
5. gt F NN LT m E141 8 12 LI 1 54 LI IEEE T LITTLE CECCOLI gt a an Mum L 4 f TOC MM jenan _ II HH mu sim 22 ip MM Tu HEHHEE CET PEPE Eo Define and Mesh Blank 1 Click the Blank button to display Blank Generator dialog box Die Simulation Single action Inverted draw Upper Tool Available Upper Tool Blank Parameters Part Material Thickness Tool Control Tool Travel Velocity 5000 00 Upper Binder Farc Binder Close Velocity 2000 00 Lower Binder Force 1200000 00 Lower Binder Travel 50 00 Lance 0 Trim 0 Advanced Help Apply Undo Preview submit Job Report Exit 16 eta DYNAFORM Training Manual DIE SIMULATION SETUP Blank generator E 2 Inthe Bl
6. 2000 00 Lower Binder Force 200000 01 Lance 0 Trim 0 Advanced Help Apply Unde review Submit Job epar Exit V Define Tool Control 1 Use the default Tool Travel Velocity and Binder Close Velocity 2 Toggle on the Lower Binder Force and Lower Binder Travel Set the value1334000N for Lower Binder Force Set the value 65mm for Lower Binder Travel as in the following figure 22 eta DYNAFORM Training Manual DIE SIMULATION SETUP Die Simulation Draw Type single action Inverted draw Upper Tool Available Upper Blank Blank Parameters Part Material Thickness Symmetry BLK BH180 0 80 Tool Control Tool Travel Velocity 5000 00 Binder Close Velocity 2000 00 Lower Binder Force 1334000 00 Lance 0 Trim 0 Advanced Help Apply Unde review submit Job Exit 3 Select Apply and the program will automatically create mating tools position the tools and generate the corresponding travel curves 4 Select Preview to check the tooling motion Compare your display with the illustration shown below eta DYNAFORM Training Manual 25 DIE SIMULATION SETUP STEP 5571814dE 8B1 Binder Closure PUNCH PUSI 509 38 DIE PUST BINDER POSI P X ETA DYNAFDORH VI Define Drawbead Next step 15 to define the drawbead for the simulation analysis 1 Click the Drawbead button to open the Drawbe
7. to select the draw type and available tool first In this application the draw type 15 Single action or Inverted draw The available tool is the Upper tool Die Simulation Draw Type Upper Taol Available Upper Tool Blank Parameters Material Thickness Tool Control Tool Travel Velocity 5000 00 Binder Close Velocity 2000 00 Lower Binder Force 200000 00 Lower Binder Travel 50 00 Lance 0 Trim 0 Advanced Help Apply Unde Preview Submit Job Exit 3 Define the tools and blank by clicking the appropriate buttons eta DYNAFORM Training Manual 1 DIE SIMULATION SETUP II Define Tools To define the Upper Tool 1 Click the Upper Tool button and then select the Select Part button from the Define Tool dialog window Define Upper Tool Include Part List Define Tool 2 Click Add Elements from the Define Upper Tool window 3 Click the Display button in the Select Elements dialog box to select all elements 12 eta DYNAFORM Training Manual Select Elements Select by Cursor Alin Region Boundary Exclude Selected 30469 Reject Last Selection DIE SIMULATION SETUP 4 Toggle on the Exclude option and select the surfaces on binder surface by using Select by surface The elements on binder surface are excluded eta DYNAFORM Training Manual 13 DIE SIMULATION SETUP Select Elements Angle 0 select by Range
8. EE 22242542242 TITLE HIER 5 22522552054 HU Hiii Hu H MISLI OHI IDEM MN TH T 844 Hd trit rd ree Ft FI j e ERE cM d nn d H imime Hirt LI iit anes rH 44 H t HEHEHEH 4444 M Lir ILI t rir i eee n LLLELLELLL Lii MM MA itt MINER tM 1H eM TESTIS IGE Hinc H 1 HATH Hi n H T LED t bb ee 44 HH HTHTHTI ae 117 14 LL eee LUNUHZBHUNSGIUS _ nene Hin gt Ctt rire Sree M 1 if IE 41121 Hil M 8 ees EI e elim cM H eee d 9 Save database IV Defining the Blank Material The u
9. M Training Manual TOOL PREPARATION bead igs 2013 7 2 10 437 IGES File 172KB Recent Places blank igs 2014 5 7 16 10 IGES File 1KB Die upper igs 238 IGES File Libraries 1 Computer D Network File name Die upperigs Files of type IGES igs iges Import Lines Surfaces Al Files Cancel Auto Mesh Mesh Param 4 After reading in the data file verify the display looks the same as the illustration shown below Y ETA DT NAF OR II Meshing Die The meshing of the die part tool done in eta DYNAFORM is carried out using the Surface Mesh function This function will automatically create a mesh based on the provided surface data This is a very quick and easy way of meshing the tools eta DYNAFORM Training Manual 3 TOOL PREPARATION 1 Select Surface Mesh from the Mesh tab as shown below Tool Preparation D Eval File Display Geometry Mesh Symmetry Tipping Boundary Fill Organize 2 In displayed Surface Mesh dialogue window default values will be used for all fields Surface Mesh Mesher Tool Mesh ww Connected UnConnected Boundary Check Refine Sharp Angle Re mesh Farameters Max Size Min Size 0 50000 Chordal Dev 0 15000 Angle 20 00000 Gap Tolerance 2 50000 Ignore Hole Size o 00000 SetBy Parts Accept Mesh Yes Mo Exit 3 surfaces of D
10. ad dialog box as illustrated in the following figure Die Simulation Draw Type Single action Inverted draw Upper Tool Available Upper Tool Blank Parameters Part Material Thickness Tool Control Tool Travel Velocity 5000 00 Binder Close Velocity 2000 00 Lance 0 Trim 0 Advanced Help Apply 24 eta DYNAFORM Training Manual DIE SIMULATION SETUP 2 3 Switch the file type to iges and select drawbead file bead igs eta DYNAFORM Training Manual 25 DIE SIMULATION SETUP LU bead igs Recent Places blank igs 20 HERE 16 10 IGES File 1 Die upper igs 2004 7 23 8 40 IGES File 9 151 Desktop libraries A Computer PM A Network File name Files of type 15250 198 All Files Cancel 2 P 4 Use default mesh parameters and click Apply to generate the line drawbead Select all the Draw beads in the left side list Click Select in Lock tool and select BNDROOOO from the Select Part list Click OK to exit Lock the drawbead to part BNDROOOO Lock tool 6 Once the sheet is defined the program will calculate the full lock force and set Force Percentage 50 0 of each bead 2 1 H R 1 T lt 3 lw Ii
11. ank Generator Outline click the Import button to import the blank outline eta DYNAFORM Training Manual 17 DIE SIMULATION SETUP 3 Go to the training files located Locate the file Blank igs and import it Click OK to dismiss the Import File dialogue window Mame Date modified Size bead igs 2013 7 2 10 47 IGES File 172 KB blank igs 2014 5 7 16 10 Die upper igs 2004 7 23 8 40 IGES File 9 161 4 Click the Select Line button in Blank Generator Outline to select the imported blank outline Select line Define Create hole Create weld Create Laminate Delete Export From BSE Mesh Blank mesh 5 After selection click OK to exit Select Line dialog box 6 Click the BLANK MESH button to enter the Blank Mesh dialog box 18 eta DYNAFORM Training Manual DIE SIMULATION SETUP Blank generator 7 User can change Element Size to 16 Blank mesh 8 After you have entered the variable press OK and the program will automatically save the created blank mesh as another BLK part Compare your mesh with the following picture eta DYNAFORM Training Manual 19 DIE SIMULATION SETUP tt 241211221 Hun T T Hirn HEHEH Hii E
12. bove the Model Check Repair dialogue consists of several functions that enable the users to check the quality of mesh Only two of the functions are described in this training manual Please refer to eta DYNAFORM online help for information regarding to the remaining functions Auto Plate Normal EJ 1 Click Auto Plate Normal from the Tool Preparation Mesh dialogue A new dialogue will be displayed 2 The displayed dialogue prompts you to pick an element to check all the active parts or an individual part for element normal consistency Select an element on the Die part 3 arrow will be displayed showing the normal direction of the selected element A prompt will ask Is normal direction acceptable 8 eta DYNAFORM Training Manual TOOL PREPARATION eta DYNAFORM Question Is normal direction acceptable X Ez Wr Clicking Yes will check all elements and reorient the part as needed to the direction that 15 displayed Clicking No will check all elements and reorient as needed to the opposite of the direction that 15 displayed In other words click Yes if you want the normal to point in the direction of the displayed arrow or No if you want it to be the opposite As long as the normal direction of most elements in a part is consistent the program will accept that If half of the total element s normal is pointing upward and other half pointing downward the result will be flawed 4 Now that the Die part eleme
13. eta DYNAFORM Die Simulation Training Manual Version 5 9 2 1 Engineering Technology Associates Inc 1133 E Maple Roa ad Su ite 200 48083 Tel 248 729 3010 Fax 248 729 3020 Email support eta com Engineering Technology Associates Inc ETA the ETA logo and eta DYNAFORM are the registered trademarks of Engineering Technology Associates Inc All other trademarks or names are the property of the respective owners 1998 2014 Engineering Technology Associates Inc rights reserved TABLE OF CONTENTS TABLE OF CONTENTS 1 HON 1 DATABASE MANIPULATION uuu eiui iNOS I Creating an eta Dynaform Database and Analysis 2 TOOLCPREFARA TION c d l Fons uM Pix P ___4_ _ 1 MEE 5 H Mesh Check and IRANI acca ence cetoe esa cuoc 000 e RREUR BEER CIS d MR EEOSE REAREN 7 ME S TOS B mee 11 Die simulation MME ICO as Feu dao Mee 11 E A 12 Hr Detine and Mesh 16 IV Defining the Blank Material 20 25 Dene f
14. gs from UserSetup Analysis Configuration menu Note Draw Type should accord with press type in practice The parameters define the working direction of default punch and die If you are not sure or operating new technique you should select User Defined 2 eta DYNAFORM Training Manual DATABASE MANIPULATION You can also refer to the eta DYNAFORM User s Manual for information about all of the Draw Type functions File Types Eta DYNAFORM has the ability to read the following types of input files CATIAS CATProducO 9 STEP stp step 18 DYNAIN dynain eta DYNAFORM Training Manual 3 TOOL PREPARATION TOOL PREPARATION Tool Preparation is a very important step contributing to a successful simulation The tool will be imported and meshed in Tool Preparation I Import Die Geometry 1 From menu bar select D Eval Preparation Utilities View Help AutoSetup QuickSetup UserSetup SCP OP PostProcess Option D Preparation Binder Modification Trim Check Die Design Check Die Simulation 2 From menu of Preparation select File Import Tool Preparation D Eval Symmetry Tipping Boundary Fill Replace Mesh Symmetry Boundary Fil Organize Go to the training files located Locate the file Die_upper igs and import it Click OK to dismiss the 3 Import File dialogue window eta DYNAFOR
15. ie will auto be selected Click the Apply button on the Surface Mesh dialogue 6 eta DYNAFORM Training Manual TOOL PREPARATION 4 The mesh will be created and will be displayed in white To accept the mesh click the Yes button when prompted Accept Mesh in the Surface Mesh dialogue Check your mesh with the mesh displayed below ree ee 1 r oh w E He 3 5 Ls T ias er MS au ha E gunnasununaueanaaumanaay Em amat I aan y 3 m 7222 3 x T a idi a E LLELLTL A Y ETA DYNAF RR 5 Press Exit on the Surface Mesh dialogue to exit the function Now that we have the Die meshed you can turn off the surfaces and lines by turning off Surfaces and Lines in the Display Option dialogue This makes it easier to view the mesh 6 Save the database III Mesh Check and Repair As the mesh has been created its quality has to be checked to verify that there aren t any defects that could cause potential problems in the simulation All the utilities used for checking the mesh are located under the Tool Preparation Mesh Edit eta DYNAFORM Training Manual TOOL PREPARATION Tool Preparation D Eval File Display Geometry Mesh Symmetry Tipping Boundary Fill Organize lala As shown a
16. mouse the frame you would like to view from the frame list Users can also drag the slider of frame number to select the frame accordingly eta DYNAFORM Training Manual 33 POST PROCESSING with eta POST Frames Single Frame Y Resel 1 1120 330933 367 301331 340 706970 316 594543 291 080429 185 562729 120 044540 64 789185 60 942017 54 9050473 53 920532 46 897034 44 057153 39 877441 25 1 IV Check the forming Result of FLD In this step we check the forming result based on the FLD plotting Turn off all parts except BLANK part and then plot the last frame as shown below FRAME 21 STROH 0 000000 middle Heer V Check the forming Result of THICKNESS In this step we check the forming result based on the THICKNESS and THINNING plotting 1 Pick THICKNESS from the result manipulation menu bar 34 eta DYNAFORM Training Manual POST PROCESSING with eta POST 2 Select THICKNESS from the Current Component list 3 Then select last frame to plot the thickness result 4 Select THINNING from the Current Component list to plot thinning result 25 00 22 10 19 20 16 30 13 40 10 50 7 60 4 70 1 80 1 10 4 00 eta DYNAFORM Training Manual 35
17. nts are consistent Display Model Boundary This function will check the mesh for any gaps or holes and highlight them so you can manually correct the problem 1 Select Display Model Boundary from the Tool Preparation Mesh dialogue window Minor gaps in the tool mesh are acceptable Click the isometric view and make sure that your display looks like the following eta DYNAFORM Training Manual 9 TOOL PREPARATION S NR 5 2 Turn off all of the elements and nodes from the Display Options dialogue Note the boundary lines are still displayed This allows you to inspect any small gaps that might be difficult to see when the mesh is displayed The results are shown in the following picture 3 Check for overlapping elements Delete the duplicate elements if they were found 4 Save your database 10 eta DYNAFORM Training Manual DIE SIMULATION SETUP DIE SIMULATION SETUP In Die Simulation use INCSolver to do the sheet metal simulation analysis Before simulation it needs to define tools and blank I Die Simulation Interface 1 Select the D Eval menu D Eval Die Simulation File Parts BSE PNE AutoSetup QuickSetup UserSetup SCP PostProcess Option utilities View Preparation Binder Modification Trim Check Die Design Check Die Simulation 2 shown in the following the Die Simulation menu the undefined tools are highlighted in red The user needs
18. omputing platforms in Windows environment Note This manual is intended for the application of all eta DYNAFORM platforms Platform interfaces may vary slightly due to different operating system requirements This may cause some minor visual discrepancies in the interface screen shots and your version of eta DYNAFORM that should be ignored eta DYNAFORM Training Manual 1 DATABASE MANIPULATION I Creating an eta Dynaform Database and Analysis Setup Start eta DYNAFORM 5 9 2 1 For workstation Linux users enter the command df5921 default from a UNIX shell to start eta DYNAFORMS 9 2 1 For PC users double click eta DYNAFORM 5 9 2 1 DF5921 icon from the desktop or choose et DYNAFORM from the program group After starting eta DYNAFORM a default database file Untitled df is created Users can save the database to the designated working directory Go to File Save as type Die Simulation and click Save to dismiss dialogue window Save As Mame Date modified Size items match your search Recent Places Desktop Libraries Computer Save as type database 7 07 m File name Simulation Database Unit Click UserSetup Analysis Configuration menu The default unit system for new eta DYNAFORM database is mm Newton Second and Ton The default setting for draw type is double action toggle draw The user is able to change these default settin
19. r COMMAND COMPLETED READ COLORBAR CONFIGURATION FILE Fill Color Element Edge Shrink PLEASE WAIT 2 COMMAND COMPLETED Hidden Surface Normal Background 3 The fas file is now completely read in You are ready to process the results using the result manipulation menu bar as shown below II Animating FLD eta POST can animate deformation FLD thickness and various strain stress distribution of the blank To do this refer to the following examples FLD 1 Pick FLD from the result manipulation menu bar 2 Select Middle from the Current Component list 3 SetFLD parameters n t r etc from FLD Curve Option 4 Select Edit FLD Window to define location of FLD plot on the display window 5 Click the Play button and the animation will begin 6 Click the Stop button 32 eta DYNAFORM Training Manual POST PROCESSING with eta POST FLD Operation Layer MIDDLE 5 FLD Curve Option List Value FLD Reversed Mapping Frames All Frames Y Resel mm x na ome OOo Ss Oo 1 c j i Ma I uod Li Frames Second 20 III Plotting Single Frames Sometimes it is more convenient to view single frames rather than the entire animation To do this select Single Frame from the Frame combo box Then select with your
20. ser needs to define the material and thickness For the blank thickness enter the number in the thickness field In this case we will set it to 0 8mm The blank material can be selected from the Material Library under the material definition window 1 Click the MAT0000 button under Material text Die Simulation Draw Type Upper Tool Available Upper Blank Parameters Part Material Thickness i BLK 0000 1 00 Tool Control 5000 00 Tool Travel Velocity Lower Binder Force Binder Close Velocity 2000 00 Lower Binder Travel 5000 Lance 0 Trim 0 Advanced Help Apply ndo Preview Submit Job Exit 2 Click the Material Library button to open the material lib eta DYNAFORM Training Manual 20 Material Material MATOOOO DIE SIMULATION SETUP Material Library Standard United States User Defined Help Material Library STEEL 3 Mild BH210 BH250 BH280 BH300 DR210 H High Ha Advanced High 3 Select BH180 from Unite States standard Then exit Material definition dialog box 4 Input blank thickness 0 8mm eta DYNAFORM Training Manual 21 DIE SIMULATION SETUP Die Simulation Draw Type single action Inverted draw Upper Tool Available Upper Blank Blank Parameters Part Material Thickness Symmetry BLK BH180 0 80 Tool Control Tool Travel Velocity 15000 00 Binder Close Velocity
21. stProcessor exe The eta POST can also be accessed from the programs listing under the start menu under eta DYNAFORM 5 9 2 1 The eta D YNAFORM Menu Bar AutoSetup QuickSetup UserSetup SCP option Utilities View eta Post 1 From the File menu of eta POST select Open The Open File dialogue will be displayed 30 eta DYNAFORM Training Manual POST PROCESSING with eta POST N m te modified i Favorites Ime WE Desktop DIE Simulation Model 2014 5 7 16 10 File folder Downloads Die Simulation 1 FORM FAS 2014 5 8 10 47 FAS File isl Recent Places Libraries Eg Documents a Music Pictures Videos 188 Computer Local Disk C Tool D Project E Local Disk F Data Backup H Die Simulation 1 FORM FAS 2 Select Die Simulation01 FORM FAS from the Files of Type list This option will allow you to read in the fas file Navigate to the directory where the result files were saved be sure you have the correct file of type selected pick the fas file and click Open as shown in the figure below eta DYNAFORM Training Manual 31 POST PROCESSING with eta POST ETA Post Processor 1 8 1 E DF592_TestFiles Application_Manual Die_Simulation Die_Simulation01_FORM FAS eno Frame Number 2 A ETA POST e Shade 7 Smooth Shade Material Colo
22. ulationDie Simulation The INCSolver displays a DOS window showing the status of the job You will notice that some model information is given The next step 15 to Proceed to section POST PROCESSING with eta POST for post processing DAT E CMM DD YYD 5 08 2014 88 013 19 88 54 11 Honlinear Dynamic Explicit Method SolvertINGSolver gt Engineering Technology Associates has developed a specialty Dynamic Non linear Transient Finite Element Program INCSolver for sheet metal forming problem ETA 99 1133 E Maple Rd Ste 200 Troy HI 48883 Version 598 Date 87 31 2813 START SOLUER FOR STAMPING FORMING SIMULATION DAT E CMM DD YY gt 5 88 2014 TIMECHH 55 E 18 87 03 51 am 1 DISPZ H 2655E H7 1881 DISPZ H 266HE H1 2001 DISPZ 8 2127 3881 DISPZ 2 872 eta DYNAFORM Training Manual 29 POST PROCESSING with eta POST POST PROCESSING with eta POST The eta POST reads and processes all the available data in the d3plot file For more information about them please refer to eta post User s Manual In this case we will just read the fas file which is generated from INCSolver I Reading the Results File into the Post Processor To execute eta POST click Post Process from eta DYNAFORM menu bar The default path for eta POST is C Program Files Dynaform 5 9 2 1 In this directory double click the executable EtaPo
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