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DYNAFORM New Features DYNAFORM Team 10/2011
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DYNAFORM - LS-DYNA Based Die System Simulation Package
BSE (Blank Size Engineering with MSTEP One-Step Solution) Blanking, Nesting, Material Cost Estimation One-Step Formability Simulations DFE (Die Face Engineering) Binder and Addendum Generation, Drawbead Layout NURBS CAD Surface Based Technology Associability – Binder / Addendum Profile / PO Line Re-use existing die face design for new product Incremental solver – INC Solver for design iterative studies Formability (LS-DYNA based Forming Simulation Solution) Accurate Solution for Formability in Springback and Springback Compensation Massive Parallel Processing (CPUs) for analysis lead-time reduction DSA (LS-DYNA based Die System Analysis) Die Structure Integrity (DSI) Sheet Metal Transferring & Handling (SMTH) Scrap Shedding/Removal (SSR) 2
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New & Enhanced Features/Functions in DF5.8.1
Many significant enhancements in all modules BSE, DFE, INC Solver, Blank Generator, AutoSetup, Job Submitter Improved GUI which will provide the flow of the process for setting up analyses. There is no license key change, existing DF5.8 license key is good for DF Down load from web site and move the license key from DF 5.8 folder to the DF folder
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New features of Dynaform
New Binder Functions in Dynaform 5.8.1
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New & Enhanced Features/Functions in BSE Module
Processing Procedure Re-arranged Enhancement in Nesting Processing Nesting Calculation to improve the calculation of material utilization rate
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Outline Finished items: Create Binder surface together with mesh
Depth Check in Binder Auto Move Binder in Part on Binder Simultaneously Select Symmetrical Elements in Part on Binder
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1. Create Binder surface together with mesh
In DF5.8.1, the program will auto mesh Binder with below binder operation: Create Binder; Modify Binder ; Part on Binder; Butterfly. DF5.8 DF5.8.1
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2. Depth Check in Binder Add a check box “Depth” in Binder to check the Draw Deph
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3. Auto Move Binder in Part on Binder
If there is a larger gap between Binder and Product, then do Part on Binder operation, it often cannot get good result. In DF5.8.1, after click Apply to do Part on Binder, the program will auto to move binder to the closest position of Product, then do the Part on Binder operation.
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3. Auto Move Binder in Part on Binder
The below are the Part on Binder result of DF5.8 and DF5.8.1. The white region will be on binder, and the gap between binder and product is 80mm. DF5.8.1 Result Note: Not toggle on Fix Boundary. DF5.8 Result
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4. Simultaneously Select Symmetrical Elements in Part on Binder
If symmetry plane has been defined for symmetric part and Double-Attached Half/Full, it will support to simultaneously select elements on both sides in Part on Binder.
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New features of Dynaform
New DFE Functions in Dynaform 5.8.1 Date: 08/31/2011
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Outline New functions as below Load and mesh automatically;
Only add Middle surfaces part in Current Tool; Only add Top or Bottom surfaces part in Current Tool; Define Tipping before Symmetry; Auto check symmetry plane for full input symmetrical part; New Auto Tipping Method ‘Element Normal’; Parameterization Inner Fill, support to simultaneously create and edit symmetrical holes; Parameterization Boundary Smooth, support to simultaneously create and edit smooth features; Simultaneously create and edit symmetrical control points on double fill control line; Simultaneously create and edit symmetrical Side Step features; Product Replace; Update Boundary Fill features
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1. Load and mesh automatically
Outlines of Import Options: Provide option: Import Line, Import Surface and Auto Mesh in Import GUI. The options are included in Tool preparation of BSE,DFE and Auto Setup modules. Description: The options under file menu of Tool preparation. User can select line or surface option to import models. When selected import surface, the mesh option will be active, and user can set the mesh parameters.
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2. Only add Middle surfaces part in Current Tool;
In Preparation, the program will automatically add the middle surface layer to the current tool and remove other layers in the current tool after the Generate Middle Surface is generated. Current Tool List Before generate middle surface Current Tool List After generate middle surface
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3. Only add Top or Bottom surfaces part in Current Tool;
In Preparation, after separate surfaces, the dialog box Add to current tool pop up. Allow user to add the top or bottom surface layers of the part to the current tool, and remove other layers in the current tool. Current Tool List Before separate surface Current Tool List After separate surface
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4. Define Tipping before Symmetry
Add a option in Edit Default Config to define Tipping before Symmetry
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5. Auto check symmetry plane for full input symmetrical part
In DF5.8.1, add Apply button to check that the product is symmetrical about defined symmetry plane. If it is symmetrical, the symmetry plane is successfully defined. If not, the user needs to redefine the symmetry plane. Note: In DF5.8.1, DFE support to simultaneously create features on both sides for symmetrical part or double-attached. So we need to define the right symmetry plane, that it will work normally. DF5.8 DF5.8.1
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6.New Auto Tipping Method
Element Normal: New auto tipping method, use the average normal of selected elements as Draw Direction. DF5.8 DF5.8.1
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7. Parameterization Inner Fill
New changes in Inner Fill as below: Parameterization Inner Fill Simultaneously fill selected symmetrical holes Simultaneously add and edit profile on symmetrical holes. Simultaneously add and edit profile on hole which cross symmetry plane. DF5.8 DF5.8.1
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7. Parameterization Inner Fill
Parameterization Inner Fill: Use new GUI in DF5.8.1, save all fill features, parameters and profile in database, support to re-edit. Auto: Fill all holes one time Manual: File one hole one time List: Record all filled holes Profile: Add and edit profile on hole region to obtain special fill result
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7. Parameterization Inner Fill
2. Simultaneously fill selected symmetrical holes one time. Select one hole, the symmetrical will auto highlight same time. Symmetrical holes Before Fill After Fill
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7. Parameterization Inner Fill
3. Simultaneously add and edit profile on symmetrical holes
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7. Parameterization Inner Fill
4. Simultaneously add and edit profiles on hole which cross symmetry plane. Note: 1. Add a profile which will crossing symmetry plane, it will auto be vertical to symmetry plane. 2. Support to simultaneously create symmetrical profiles on both sides. 3.Support to simultaneously edit both symmetrical profiles.
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8. Parameterization Boundary Smooth
New Changes in Boundary Smooth as below: Change the name from “Outer Smooth” to “Boundary Smooth” Parameterization Boundary Smooth Support to create boundary smooth feature on inner boundary Simultaneously smooth boundary on both side Simultaneously edit smooth region Simultaneously add and edit profile Create smooth features cross symmetry plane DF5.8 Outer Smooth DF5.8.1 Boundary Smooth
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8. Parameterization Boundary Smooth
Parameterization Smooth: save all fill features, parameters and profile in database, support to re-edit. Global: Smooth selected one time Local: Smooth by defined boundary on the selected boundary List: Record all smooth features Boundary: Edit position and shape of smoothed boundary. Profile: Add and edit profile on smooth feature Note: 1. After click Add, user need to select out boundary or an inner boundary to smooth firstly. 2. All smooth features, parameters and profile will be saved in database, support to re-edit them.
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8. Parameterization Boundary Smooth
3. Support to Create smooth feature on inner boundary: Select a hole as smooth boundary. After click Add button, then select a hole boundary to smooth. Note: When smooth hole boundary, only Local method can be used.
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8. Parameterization Boundary Smooth
4. Simultaneously smooth boundary on both side: Program will create smooth result on symmetrical boundary one time
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8. Parameterization Boundary Smooth
5. Simultaneously edit End Points position and edit smooth boundary’s shape
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8. Parameterization Boundary Smooth
6. In DF5.8.1, support to Simultaneously add and edit profile, to obtain special smooth result
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8. Parameterization Boundary Smooth
7. The Local Smooth supports to cross Symmetry Plane to create Boundary Smooth After defining a symmetry plane and selecting a point on the boundary, the Symmetry Option dialog box will display. Click the Cross Symmetry Plane option, and the program will automatically connect the ends of the two sides of the symmetry plane to generate the smooth outline, The created local smooth outline will pass through the symmetry plane. Toggle on the option
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9. Simultaneously edit Double Fill
Use new Curve Editor to edit Double Fill control lines, and support below symmetry operation: Add Point Remove Point; Modify value in Curve Editor dialog; Move point in display region. Note: About the Curve Editor, please check section 7.5 in DF5.8 User Manual
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10. Simultaneously create and edit Side Step
Support to symmetrically create and edit Side Step Re-arrange GUI Support to create Side Step on Inner Boundary Create on both side for symmetrical die face same time Support to cross Symmetry Plane to create Side Step
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10. Simultaneously create and edit symmetrical Side Step
Re-arrange GUI DF5.8 DF5.8.1
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10. Simultaneously create and edit symmetrical Side Step
2. Create Side Step on Inner Boundary. Clicking Add button and selecting four control points on the inner boundary, the Side Step will be created on the inner boundary
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10. Simultaneously create and edit symmetrical Side Step
3. Simultaneously create symmetrical Side Simultaneously select end point on both side. Simultaneously edit control line on both side.
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10. Simultaneously create and edit symmetrical Side Step
4. Support to cross Symmetry Plane to create Side Step When the Side Step is created on the Symmetry Part, the Symmetry Option dialog box will display. Click the Cross Symmetry Plane option, and the program will automatically connect the control points of the two sides of the symmetry plane to generate the control line of Side Step. The created Side Step will pass through the symmetry plane. Toggle on the option
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11. Product Replace 10. Product Replace: Add a new option in Preparation File menu. Allow the user to replace the initial product(Has created die face) with the modified product. Replace the existing product by importing a new product. Note: As the initial product has created the die face, the program will automatically mesh the new product imported and define the die face type to adjust the tipping.
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11. Product Replace Product Replace for Double_Attached
If the initially defined product type is Double-Attached, click Replace button, there are the Left and Right options, which allows the user to replace the Left and Right simultaneously, or only one of them.
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11. Product Replace Auto Mesh: As the initial product has created the die face, the program will automatically mesh the new product imported and define the die face type to adjust the tipping. Mesh Parameters: Allow user to modify the mesh parameters.
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12. Update Boundary Fill features
When the user replaces the current product, or changes the part shape or part position, or edit created boundary features by other operations, the Update button will turn to red. Click this button and the program will automatically update the created boundary fill features.
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New Addendum Functions
New features of Dynaform New Addendum Functions in Dynaform 5.8.1 Date: 09/22/2011
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Outline Finished items:
Symmetrical Create Addendum: Outer, Inner or Corner. Symmetrical Edit Addendum Feature Line Symmetrical Edit and Delete Profile Symmetrical Orient Profile Direction Add Trim Binder in Addendum New Develop Trim Line function: Geometry and MStep Quick Link to AutoSetup
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1. Symmetrical Create Addendum
Symmetrical Create Addendum: Outer
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1. Symmetrical Create Addendum
Symmetrical Create Addendum: Inner
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1. Symmetrical Create Addendum
Symmetrical Create Addendum: Corner.
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2. Symmetrical Edit Addendum Feature Line
Note: If symmetry plane has been defined for symmetric part and Double-Attached Half/Full parts, Merge, Split and Combine functions will be de-activated.
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3. Symmetrical Edit Profile parameters, Symmetrical Insert and Delete Profile
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4. Symmetrical Orient Profile Direction
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5. Add Trim Binder in Addendum
Move Trim Binder from Modification to Addendum DF5.8 DF5.8.1
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6. New Develop Trim Line function: Geometry and MSTEP
In DF5.8.1, provide Geometry method and One Step(MSTEP) method to develop trim line in Addendum. After select MSTEP, click Apply, the program will auto call MSTEP solver to develop trim line DF5.8 DF5.8.1 Geometry DF5.8.1 MSTEP Note: Now using MSTEP to develop trim line, the result is unstable. Pro. Bao is still improving it, and do not know when he will finish it.
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6. New Develop Trim Line function: Geometry and MStep
Use new Curve Editor to edit trim line. Curve Editor
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7. Quick Link to AutoSetup
The function is used to auto assign DFE Die Face to Forming Tools in AutoSetup. Addendum AutoSetup Note: Only binder has been trimmed, AutoSetup button will be activated.
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7. Quick Link to AutoSetup
After Forming tools have been assigned, if user edit die face in DFE, need to click DFE Assign button to re-assign tools.
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New features of Dynaform TWB and Trimming in INC Solver
DF5.8.1 Date: 09/20/2011
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New functions in INC Solver
New functions in INC Solver include: Support Tailor Welded Blank New Curve Editor in Lance Support Trimming operation Assign CPU Number
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New functions in INC Solver
Master Interface DF5.8 DF5.8.1
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Tailor Welded Blank TWB Parts Display: In DF5.8.1, it will display all parts of tailor welded blank. DF5.8 DF5.8.1
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Tailor Welded Blank Define TWB : In DF5.8.1, user can add more than one parts, or create weld line to define TWB in Blank Generator. Create Weld Line Result DF5.8 DF5.8.1 Note: 1. The parts of TWB should be connected. 2. There are some new functions of Blank Generator, please check the related new feature PPT of Blank Generator later.
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New Curve Editor in Lancing
In DF5.8, after click Add button, only allow to select existed curve. In DF5.8.1, after click Add button, user can select or create curve in Curve Editor, and also can edit the curve DF5.8 DF5.8.1
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Trimming operation Trimming: There are two trimming operations: Trimming and Hole. Note: 1. The trim line must be closed. 2. Only allow to define one Trimming curve, not support to trim for double-attached. 3. Hole direction must parallel to Z-axis, not support CAM.
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Trimming operation Create and Edit trim curve or hole: Use ne Curve Editor to select, create and edit curve.
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Assign CPU Number Assign CPU number:
Single: Run a job by using one CPU. After setting Single, the program will auto call ‘DEMS_SC.exe’. Multi: Run a job by using all free CPU. After setting Multi, the program will auto call ‘DEMS_MC.exe’. Note: New functions of Job Submitter is still developing, please check the related description later.
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TBD—Sample 01 Tailor Welded Blank FLD Thickness
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Trimming—Case1 Trim Line Result
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Trimming—Case2 Result
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Limitation Now the solver do not support to trim with more then one closed trim line at one time. The below case is a double-attached, there two closed trim lines. The trim result will be wrong.
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Limitation Hole direction must parallel to Z-axis, not support CAM.
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Mapping Solid Mapping Solid: New function in Blank Operation under User Setup and Blank Generator. It is used to mapping shell element to solid. UserSetup Blank Generator
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Mapping Solid Solid Thickness: Solid Thickness is from the result the shell elements Layers: The number of layers in the solid must be the same as the number of integration points in the shell elements. Top surface element bottom surface element Note: Take the shell elements as middle surface elements, according the thickness and the integration points auto create top surface elements and bottom surface elements.
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New features of Dynaform
New Blank Generator Date: 07/05/2011
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Outline New Blank Generator include below functions:
Import Blank Surface; Import Blank Outline; Provide two mesh method of Blank: Blank Mesh and Part Mesh; Add Modify Boundary Nodes in Part Mesh Support New Blank Generator in Quick Setup
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Blank Generator GUI DF5.8 Parts DF5.8.1 Parts DF5.8 Outline
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1. Import Blank Surface Import Blank Surface: Add Import Surface button in Parts page, used to import blank surface. DF5.8 DF5.8.1
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1. Import Blank Surface Click Import surface button, Import dialog will pop up. Only surfaces will be imported, and support nine geometry format. Note: If user want to import other geometry surface, need to install CAD Translator 3.0 or NX Translator 3.0. Import Dialog
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2. Import Blank Outline Import Blank Outline: Add Import button in Parts page, used to import blank outline. The GUI also have been re-arranged, Export button has been moved under outline list Note: For the blank outline will include outer, holes and weld line, Import function just import the geometry line into Dynaform. So user need to select related lines to define outer ,hole and weld line separately. DF5.8 DF5.8.1
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2. Import Blank Outline Click Import button, Import dialog will pop up. Only surfaces will be imported, and support nine geometry format. Note: If user want to import other geometry line, need to install CAD Translator 3.0 or NX Translator 3.0. Import Dialog
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3. Two Mesh Methods of Blank
In DF5.8.1, Provide two mesh methods: Part mesh and Blank mesh, to mesh blank surface or blank outline. User can select Mesh method under Mesh Type menu. Note: After select one type of Mesh, the button in Mesh Group will change to corresponding mesh name: Blank mesh or Part mesh. DF5.8.1 Blank Mesh Method DF5.8.1 Part Mesh Method
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3. Two Mesh Methods of Blank
In DF5.8, Use Part mesh to mesh blank surface, and use Blank mesh to mesh blank outline. DF5.8 Part mesh DF5.8 Blank mesh
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3. Two Mesh Methods of Blank
In DF5.8.1, Provide two mesh methods to mesh blank surface and blank outline. DF5.8.1 Blank Mesh Mesh Surface DF5.8.1 Part Mesh Mesh Surface DF5.8.1 Blank Mesh Mesh Outline DF5.8.1 Part Mesh Mesh Outline
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3. Two Mesh Methods of Blank
Note: It has removed below un-used options of Part Mesh in Blank generator. In Original Part Check Surface Mesh by Part Auto Repair Part Mesh In Blank Generator Part Mesh In Surface Mesh
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4. Modify Boundary Nodes Modify Boundary Nodes: Add Modify Boundary Nodes option in Part Mesh. Allow user to modify boundary nodes. It is added in both Part mesh in Blank Generator and Part mesh in Surface Mesh. Note: Toggle on Modify Boundary Nodes, click Apply, mesh node will pop up, which will be used to modify boundary nodes of surface boundary or outline.
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4. Modify Boundary Nodes Modify Boundary Nodes: Mesh the blank according to the boundary, and allow user to add or delete control points Insert Nodes: Insert Nodes between boundary. Delete Nodes: Delete selected boundary nodes. Average Nodes: Generate a node at the middle position of two selected adjacent nodes. Merger Nodes: Merger two selected close nodes, not merge adjacent nodes. Re-space BDY Nodes: Re-space boundary nodes for equal distance. Suppress Nodes on Edges: Select common edge to suppress, node will not ne generated on suppress edge.
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4. Modify Boundary Nodes Case 1
Mesh outline Modify Boundary Nodes result Blank Mesh result
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4. Modify Boundary Nodes Case 2
Mesh outline Modify Boundary Nodes result Blank Mesh result
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4. Modify Boundary Nodes Case 3
Mesh outline Modify Boundary Nodes result Blank Mesh result
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4. Modify Boundary Nodes Case 4
Mesh Blank Surface Modify Boundary Nodes result
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5. New Blank Generator in Quick Setup
In DF5.8.1 QuickSetup and UserSetup , it supports to use New Blank Generator to generate blank. Note: For Quick Setup not support TWB, Create weld button is de-activated.
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New features of Dynaform Coil Spring Controlled Pad Force
Date: 07/28/2011
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Outline Add coil spring between tools;
Users can create the coil spring library for their own.
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GUI of Coil Spring The entry of coil spring
After activated the Springs option, user can also edit the coil spring force in the Process tab.
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GUI of Coil Spring Name – The name of the coil spring
Count – The counts of the coil springs Stiffness – The stiffness of the coil spring Initial force – The initial force of the coil spring Stroke – The stroke of the coil spring New – Create a new coil spring Delete – Delete the selected coil spring Delete All – Delete all of the coil springs Base – The tool which the coil springs connected Import – Import the data of coil springs Export – Export the defined coil springs
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Force Curve Template Standard force curve of coil spring Unit:
*type,coil_spring *name,S1 *units,N,mm *stroke,30 *stiffness,800 *init_force,4000 *end Unit: The basic unit is N and mm. Stroke: mm Stiffness is N/mm Initial force: N Users can create the coil spring library for their own based on the above template.
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Model with Coil Springs
Spring force punch binder blank die Stamping direction
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Model with Coil Springs
FEA model with coil spring Discrete element A discrete element will be created between the associated tools. The length of a discrete element is calculated based on the stroke of master tool.
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Keywords of Input Deck *ELEMENT_DISCRETE
$ EID PID N N2 VID S PF OFFSET *MAT_SPRING_NONLINEAR_ELASTIC $ MID LCD LCR *SECTION_DISCRETE $ SECID DRO KD V CL FD $ CDL TDL *DEFINE_CURVE $spring $ LCID SIDR SCLA SCLO OFFA OFFO DATTYP $ A O1 E E+03 E E+04
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Procedures Open the demo file: Coil_spring_demo1.df
Click the menu: AutoSetup -> Sheet Forming Click Tools tab Click binder from the tool list Toggle on Springs option in the Association group Click Edit to define the coil spring force
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Procedures The spring force affects on the binder.
The spring force is derived from the travel of the base tool.
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Procedures Click New to add a new coil spring
Key in the parameters of coil spring Click OK to exit
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Problem in current solution
If the initial force is not equal to zero, the result is not right. In this case, we can add rigid body stopper to avoid the bounce of the binder.
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New features of Dynaform Gas Spring Force Curve for Binder Control
Date: 07/08/2011
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New features of Dynaform Gas Spring Force Curve for Binder Control
Date: 07/08/2011
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Outline Features: Add standard gas spring force curves for binder control in AutoSetup; User can add other standard gas spring force curves; The default template of gas spring is UX Series of DADCO product;
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Force curves template Standard force curve of gas spring
*type,gas_spring *name,UX.1000 *stroke,50 *stroke_list,25,37.5,50,62.5,75,80,100,125,150,160,175,200 *pressure,150 *pressure_list,150,125,100,75,50,25,20 *units,N,mm *curve,10 0,9230 0.1,9556 0.2,9884 0.3,10289 0.4,10675 0.5,11061 0.6,11544 0.7,12046 0.8,12605 0.9,13204 *end Standard force curve of gas spring
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GUI of Gas Spring
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GUI of Gas Spring
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GUI of Gas Spring The travel (%) vs. Force curve
The on-contact force list
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GUI of Gas Spring The supported stroke list
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Keywords of Input Deck *ELEMENT_DISCRETE
$ EID PID N N2 VID S PF OFFSET *MAT_SPRING_NONLINEAR_ELASTIC $ MID LCD LCR *SECTION_DISCRETE $ SECID DRO KD V CL FD $ CDL TDL *DEFINE_CURVE $spring $ LCID SIDR SCLA SCLO OFFA OFFO DATTYP $ A O1 E E+03 E E+03 E E+03 E E+04 E E+04 E E+04 E E+04 E E+04 E E+04 E E+04 E E+04
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Procedures Open the demo file: gas_spring_demo.df
Click AutoSetup -> Sheet Forming Click the Tools tab Click the tool: binder Toggle on the Springs option Click Edit button
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Procedures Click New to create a new spring
Click Import to import a standard gas spring Select UX1000.csv Click OK Click OK to exit the Springs dialog box
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Procedures
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Procedures After the gas spring definition is complete, user can also Edit the gas spring in process tab.
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Problem in current solution
Since the on-contact force existed in gas spring, the initial force is not equal to zero, which leads to the result is not right.
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New features of Dynaform Define line bead with beam
DF581 Date: 09/30/2011
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Procedures
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New features of Dynaform Drawbead Shape Library
DF581 Date: 08/12/2011
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Outline Draw bead shape library
It provide a relationship between drawbead lock force percentage and geometry shape; A default config file is included: DynaformBDShape.config; The adjacent force percentage should be greater than 1; The draw bead shape library is used to switch the line bead to geometry bead;
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GUI of Draw Bead Shape Library
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GUI of Draw Bead Shape Library
Material type Thickness level Shape type Force percentage
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GUI of Draw Bead Shape Library
Add a new relationship between lock force percentage and shape: Shape type Rectangle Round Shape parameters Material Thickness Force percentage(%) Define the above parameters, and then click Apply. If there is no same item in the list, the force percentage will be added in the list. If same force percentage in the list, the program will pop up a question box. Click Yes to override, Click No to abort.
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GUI of Draw Bead Shape Library
Modify the relationship between lock force percentage and shape: Only the shape parameters can be modified. Modify the shape parameters, and then click Apply. If there is no same item in the list, the force percentage will be added in the list. If same force percentage in the list, the program will pop up a question box. Click Yes to override, Click No to abort.
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GUI of Draw Bead Shape Library
Delete - delete the selected bead shape Default - load the default shape library Import - import a defined drawbead shape library from a file Export - export the current defined drawbead shape library to a file OK - accept the operations and exit Cancel - reject the operations and exit
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GUI of Draw Bead Shape Library
Diagram operation: ZOOM - Press the right mouse button and move up/down MOVE - Press the middle mouse button and move Fit screen - double click the diagram area with left mouse button Modify the parameters dynamically Double click the diagram area with middle mouse button, the drag the control point or the shape edge
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GUI of Job Submitter Solver type Job list Toolbar Control parameters
Command line
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Command of Submission The unit of memory is WORD in the command line.
1 word =4 byte
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New features of eta/POST
VRML output of FLD Date: 06/16/2011
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Outline Output VRML file of FLD in eta/POST Output VRML file of FLD;
Output single frame result of FLD; Output the elements info; The nodes info is not output.
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GUI of FLD Current frame in graphic area will be output
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Procedures Open a d3plot file; Click FLD icon; Select a frame of FLD;
Click Export VRML File; Save the VRML file.
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View the VRML File User can view the VRML file with CORTONA 3D or CATIA V5 3DViewer
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