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ALGHAFORM FORUMLARI PAYLASIMIDIR
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4 AutoFormOneStep
AutoFormOneStep has been developed to recognize forming problems quickly and effectively at a very early stage of product development and to modify the part geometry accordingly. The flexible
input in AutoFormOneStep permits the creation of a binder surface including the punch opening line. Thus AutoFormOneStep is
suited for a simple feasibility analysis and additionally for a quick
verification of a tool design and the comparison of different tool
concepts. The simulation of completely designed tools can be made
in extremely short calculation times. The seamless integration of
AutoFormOneStep with the AutoFormOptimizer helps you finding optimized geometry and process parameters.
The inverse formulation of AutoFormOneStep allows for the simple and precise determination of the blank outline and thus the minimal material requirements. This opens new perspectives for
quotations/estimations as well as for tool design considering the
optimized blank and thus the minimal material consumption.
The integration with all other AutoForm products makes many
additional functions available such as AutoFormDieDesigner or
AutoFormOptimizer for the optimization of the part geometry,
binder surfaces, addenda or process parameters.
AutoFormOneStep supports five different calculation types, which
require different forming knowledge of the user and are used for
different tasks:
Part only (1-step)
boundary, the accuracy of a Part only calculation is coarse, especially along the part boundary.
This calculation type does not directly determine the flat blank but
the curved blank, which in the real forming process conforms to the
shape of the sheet after binder closure. The binder surface has to be
defined. A two step process is simulated:
Part+Binder (2step)
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As for a Part only (2-step) calculation the binder surface is determined at first binder closure is accomplished without friction and
retraining forces.
This calculation type is used for tools with a curved binder.
As for Full tool simulations the restraining forces in the binder surfaces are of essential importance for the results, the 2-step option
should be preferred otherwise the simulation assumes that the
restraining forces in the binder surface already apply for binder closure. That does not correspond to the real forming process and may
lead to a significant overestimation of strains. Besides the remarks
on the Full tool (1-step) calculation type obtain.
The necessary geometric input data for the five simulation type are
summarized in the following table:
Full tool
Full tool
(2 - step)
Part +
Binder
(2 - step)
(1 - step)
(2 - step)
part
part
part
die
die
Binder surface
no
yes
yes
no
yes
OS boundary
pb line
pb line
f line
f line
f line
OS punch
opening
no
no
yes
yes
yes
Part only
Part only
(1 - step)
Part/Tool
geometry
Legend:
pb line = part boundary line
f line = flange line
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AutoForm offers a geometry module named AutoFormPartDesigner for the advanced use of AutoFormOneStep in feasibility
analyses during part design. It makes possible the optimization of
forming parameters in the most important geometric modifications
of the part in AutoForm:
Automatic generation of variable fillets on the product
geometry
Rapid determination of the best fillet radius for forming
Determination of the die tip (drawing direction)
Automatic geometry creation to fill designed holes
Boundary fill by filling concave inlets: The accuracy and
usability of the Part only results increase significantly in
the outer boundary area of the part.
Modification of geometry regions by cutting and controlled filling
Overcrowning of entire part regions
Automatic and interactive development of binder surfaces:
The accuracy of the simulation increases significantly for
the Part only (2-step) calculation type.
Fully parametrized treatment of input data to facilitate the
optimization with AutoFormOptimizer
AutoFormOneStep provides five different simulation
types.
For certain functions described in this workshop the AutoForm
PartDesigner must be available. The respective functions are
marked.
One of the most important features of AutoFormOneStep Version.
3.1 is the greatly improved userfriendliness and the ease with
which the simulations are set up, run and evaluated. The Onestep
wizard has been developed for the Part only simulation. This wizard makes it possible to run feasibility studies quickly and reliably
considering different process parameters in a single simulation
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Lesson 2
Lesson 3
Lesson 4
Lesson 5
Lesson 6
Full tool
Tailored blank
Linear weld line
Material mark
Material lines
Drawbead
Symmetry
Optimizing the blank
Importing and exporting lines
Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Numerical optimization
Parameter study
Optimization of the force factor
Optimization of the force factor of a drawbead
Evaluating the optimization
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Fig. 1.2
OneStep wizard
Import ... > VDAFS > OK > Files: os_lesson_01.vda > OK >
afmesh_3.1 > OK
Fig. 1.3
Import geometry
Afmesh
Options for meshing the CAD data
Error tolerance: Allowable chordal error tolerance for the
meshing. Value is taken from New file dialog (Default: 0.1)
(Fig 1.1), but it can be changed. For especially small radii
(equal or lesser than 2 mm) 0.05 should be used as error
tolerance.
Max side length: Maximum element side length. Default
setting: 50.
Parameters
Faces
Layers
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Fig. 1.5
OneStep wizard
Enter a project identifier into the field Title of the OneStep wizard.
This identifier will be always be indicated in the bottom of the user
interface.
Note:
Note A title is automatically suggested including the current file
name, the user name and the date of creation.
OneStep wizard
Title: lesson_01
The following three areas of the OneStep wizard have to be specified to prepare the simulation:
Geometry
Blank
Process
Backdrafts:
Backdrafts Representation of areas containing undercuts
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Detail:
Detail Part boundary before boundary fill
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Fig. 1.10
Detail:
Detail Part boundary after boundary fill
The geometry has been completely prepared for the simulation.
Define the sheet thickness and select a material:
Defining Material Properties
Blank > Thickness: 1
Blank > Material > Import ... > Select material > zste180bhZ_1.mat
> OK
Define the restraining forces on the part boundary in the area Process. Different holding conditions can be used. The holding condition Free corresponds to ideal deep drawing, e.g. for tools without a
binder. In contrast the holding condition Locked corresponds to
stretch forming, e.g. for tools with extremely high binder pressure.
Restraining forces, corresponding to a usual tool in which material
drawin occurs, can be defined by means of weak, medium, strong
and User defined.
The current simulation will be calculated using standard settings
(Free, Medium and Locked).
The complete input for the simulation is shown in Fig. 1.11.
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OneStep wizard:
Part only simulation
wizard Prepared OneStepPart
Store the prepared simulation and start the simulation:
File > Save as ... > os_lesson_01.sim > OK
Start ... > Program: afos_3.1 > Start
Note:
Note The OneStep wizard contains a number of selected functions
for the definition of the simulation. Use the Advanced ... button to
access additional functions in AutoFormOneStep. These additional functions will be described in the following lessons.
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Fig. 1.12
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Fig. 1.14
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User interface
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Import ... > VDAFS > OK > os_lesson_02.vda > OK > Program:
afmesh_3.1 > OK
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Fig. 2.3
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Fig. 2.5
Advanced ...
The dialog AutoForm - Question pops up:
Fig. 2.8
AutoForm - Question
Finish closes OneStep wizard and opens AFOS input generator.
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Fig. 2.9
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User interface
Binder
Fig. 2.10
Binder
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Log window
The product geometry and a curved binder are shown in the main
display.
Fig. 2.12
Geometry
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Process
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Input generator
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Fig. 2.18
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Binderwrap
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Developed blank
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Part geometry
The procedure in creating and defining inputs and in running simulations of this type is as follows:
User interface
Geometry generator
File > Import > VDAFS > OK > File: lesson_os3.vda > OK
Prepare
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Sharp Edges
Go to the Fillet page to determine the sharp edges of the geometry.
Check radius: 2.00 > Check > OK
Fillet
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Local filleting
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Fillet
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Fillet
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Fig. 3.5
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Fillet page
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Tip
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Fig. 3.7
All holes > Define holes > Min size: 1.50 > Max size: 300.00 >
Apply
Use the functions of the Bndry page to fill of areas on the part
boundary:
Bndry
Add Bndr fill ... > Curve 1 > OK > Fill parameters: Bndry fill roll
radius: 300 > Apply
Note:
Note Smoothening the part boundary increases the accuracy of
the simulation results on the part boundary, especially for concave
regions.
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Binder
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Fig. 3.9
Apply
A curved binder surface has been generated. Analyze the distance
between the binder and the part in the AutoFormUser Interface.
Adjust the value range of the result scale for the current example:
Geometry generator > Display > Ranges > Min/Max Simulation
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User interface
Title
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Geometry
Fig. 3.12
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Curve editor:
editor OSPO line
The same approach using the geometry of the Bndry (Bndry) line
as the starting point for defining another line may be employed to
accomplish the definition of the OS boundary line. This line represents the outer edge of the formed sheet at the end of the forming/
drawing process. Starting from the geometry of the Bndry (Bndry)
line, Expand and Smooth options may be used to define the OS
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Fig. 3.16
Blank page
Lube
Definition of Friction
Lubrication > Constant > Standard 0.15
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Process page
Process
Control
AFOS input generator
User interface
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User interface
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Fig. 3.18
Developed blank
Binderwrap
The result of the OneStep calculation is iterated in the binder surface considering friction. Particular high strains are thus avoided for
highly curved binders.
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Binder wrap
Formed sheet
AutoFormOneStep offers among others the following results:
Distribution of strain and all dependent variables such as
sheet thickness, failure, wrinkling, hardening, forming
limit analysis and stress
Binder pressure distribution in the flange area
Distribution of sheet reaction stress
Friction shear stress
Formability etc.
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Fig. 3.20
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Tool geometry
User interface
File > Import... > VDAFS > OK > Files: os_lesson_4.vda > OK
Geometry generator
AFMesh window
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Prepare
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Model > Input generator ... > Simulation type: OneStep > OK
AFOS Input generator
Geometry > Type > Full tool (1-Step)
The predefined OS boundary has to be deleted.
Delete > Autoform - Question: Delete the current OS boundary
line? > Delete
Tool
The surfaces saved in the Part and the Binder registers are used to
automatically define the tool geometry.
Definition of the OS boundary
This line represents the outer edge of the stamped part. Again, this
may be defined as dependent upon the punch opening line.
Dependent ... > Bndry (Pre) 1 > OK > Edit > Curve editor > Global mod > Expand: 40 > OK
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Fig. 4.6
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Weld dialog
The Curve editor is opened. Define the weld line by entering two
points (x = 0/0, y = 200/-200). The start and end point of the weld line
are positioned on the OS boundary.
Note:
Note To create a vertical line, press the Shift key when setting the
end point of the weld line.
Fig. 4.8
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Fig. 4.9
Process
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Process page
Leave the default settings on the Control page unchanged and start
the simulation in the AFOS input generator.
Job > Start simulation ... > Save > Start job: Start
After simulation is completed, the results may be viewed and evaluated in the AutoFormUser Interface by reopening the simulation
file:
File > Reopen
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User interface
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Fig. 4.11
Distribution of thickness
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:
Fig. 4.12
Developed blank
You realize that the original linear weld line has moved during the
forming process. It is the objective now to keep the weld line position as it is and to optimize the weld line position in such a way that
the original blank can be formed with a linear weld line.
To achieve the objective, define material marks at both ends of the
weld line on the developed blank.
Results > Material marks ... > Set marks
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User interface
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Fig. 4.13
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User interface
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User interface
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Start the simulation and check whether a linear weld line is available in the developed blank.
Fig. 4.15
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Tool geometry
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Fig. 5.2
Import OS boundary
OS boundary > Import ... > Format: af > Vertices: use all rotate >
OK > Select a file: osboundary05.af > OK > Select curve: Curve 1 >
OK
Define the OS punch opening line now. This line is defined as
dependent on the punch opening line as specified in the DieDesigner tool geometry.
Geometry
OS punch opening
OS punch opening > Dependent ... > Select curve: Punch opening
1 > OK
Symmetry
Define the symmetryplane on the Blank page. The sheet thickness
and the material properties have already been specified.
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Blank
Fig. 5.3
Symmetry plane
Defining Drawbeads
Drawbeads may be modeled in AutoForm using a force factor to
control metal flow, without having to build the detailed drawbead
geometry into the CAD model of the tool. This gives the user flexibility in using AutoForm as a tryout tool using it to quickly compare the performance of different drawbeads visavis feasibility
requirements, and to identify the best bead configuration, based on
comparisons, without having to modify tool geometry to accomplish the same.
AFOS input generator
Add > Drawbead > Add drawbead: Use default settings > Add
drawbead
A Drawbead (Drwbds) page is added to the AFOS input generator.
Define the position of the drawbead:
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Fig. 5.4
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Using just the right mouse button would create a curved segment. It
is possible to switch the mode of an existing segment between
curved and linear modes by holding the Ctrl key down while clicking (anywhere) on the segment with the right mouse button.
Starting the Simulation
Job > Start simulation ... > Start job: Start
After simulation is completed, the results may be viewed and evaluated in the AutoFormUser Interface by reopening the simulation
file:
User interface
Fig. 5.6
Simulation results
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User interface
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Fig. 5.8
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User interface
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Lesson 6: Optimization
4. 6 Lesson 6: Optimization
This lesson describes in a simple example how process parameters can be automatically optimized using the optimization algorithm of AutoForm. Process parameters in
OneStep can be the restraining forces at the part boundary.
Fig. 6.1
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Lesson 6: Optimization
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Fig. 6.2
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Lesson 6: Optimization
ary (Forcefactor = 2.0). The start value for the restraining force is a
free part boundary (Forcefactor = 0.0).
Complete the input for force factor of the first restraining force
(design variable) by using the submenu titled Design variable
definition of the menu Add/edit design variable as follows:
Name: rest > Dependent: Independent > Start: 0 > Min: 0 > Max: 2
(Fig. 6.2) > OK
Now the background color of input field has changed to yellow.
This means the parameter is to be used as a design variable. The
name of this variable is displayed in the input field (Fig. 6.3).
Fig. 6.3
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Process
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Lesson 6: Optimization
Fig. 6.4
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Lesson 6: Optimization
Fig. 6.5
Iteration control
Keep simulations
User can specify a list of computers which can be used for optimization/parameter study:
Name: Name of computer
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Hosts
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Lesson 6: Optimization
Directory: Directory in which simulations can be stored
temporarily
#Lic: Number of AutoForm licenses on computer
#Jobs: Number of jobs, which can run in parallel
Use: Use or do not use this computer for this optimization/
parameter study.
Add host : Specify a new computer for optimization/
parameter study.
Edit host : Edit computer parameters for optimization/
parameter study.
Save hosts: Save specified parameters of computers.
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Lesson 6: Optimization
Close this menu using Cancel. Switch to the Target page (Fig. 6.7).
The target function is defined as follows:
For the whole part including the fill areas, the major strain
must be 20% below the Forming Limit Curve (FLC).
Thinning is limited to 30% and thickening is limited to 2%.
All other target values Wrinkles and Desired strain should be
deactivated (Fig. 6.7).
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Optimize
Lesson 6: Optimization
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Fig. 6.7
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Lesson 6: Optimization
Fig. 6.8
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File
Buttons
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Lesson 6: Optimization
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Lesson 6: Optimization
Fig. 6.10
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Lesson 6: Optimization
Fig. 6.11
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Lesson 6: Optimization
Fig. 6.13
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Lesson 6: Optimization
Fig. 6.15
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Lesson 6: Optimization
Fig. 6.16
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Lesson 6: Optimization
Fig. 6.18
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Lesson 6: Optimization
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