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ManufacturingSolutions

HF0150:QuickSetup
ThistutorialdescribesthestepsrequiredformodelingandrunningonestepanalysisthatcanbeperformedinHyperFormwithintheRADIOSS
OneStepuserprofile.
Thefollowingstepsareinvolvedinonestepanalysis:
1.

Geometrycleanupandmeshing

2.

Assigningmaterialsandthickness

3.

Definingsymmetry

4.

Definingblankholders

5.

Definingdrawbeads

6.

Settingthestampingdirectioneitherbytippingthepartorbyusingtheexistingpartorientationastheformingaxis

7.

Checkingforundercuts

8.

Runningtheanalysis

Exercise1:GeometryCleanupandMeshing
ThisexerciseusesthemodelfilePart1a.igs.ThefollowingimageshowstheprogramwiththeRADIOSSOneStepuserprofileandmodelfile
loaded:

Step1:Loadthemodelfile
1.

ClickFile>Import....

2.

ClicktheImportGeometryicon

3.

ClicktheSelectFilesicon

4.

ClickImportandthenclickClose.

andbrowsetothefile<installation_directory>\tutorials\mfs\hf\1Step\part1a.igs.

Step2:Geometrycleanup
1.

IntheOneSteptab,rightclickonParts>New>Pick...asshownintheimagebelow:

Note:ThecomponentnameisrecognizedautomaticallyasPartoncethemodelisloadedintothesession.
2.

Pickthepartfromthescreen.

3.

Clickonproceed.
Note:ThematerialCRDQsteelandathicknessof1mmisassignedtothepartbydefault.

4.

Rightclickonthepartlvl1andselectGeometry>RemoveHoles.

5.

Inthediameter<field,enter40.

6.

Clickontheyellowsurfsbuttontohighlightit.Clickagainandselectdisplayedfromtheextendedentityselectionmenu.Thisselectsall
theentitiesonthescreen.

7.

Clickfind.AllpinholesfoundarehighlightedwithxP.

8.

Clickdeletetoclosethehole.

9.

Clickreturntoclosethepanel.

Step3:Meshingthepart
1.

Rightclickonthepartlvl1andselectMesh>RMesh.

2.

Enterthevaluesasshownbelow:

3.

ClickonMesh....

4.

Clicksurfsandselectdisplayedfromtheextendedentityselectionmenu.Thisselectsallthesurfacesdisplayedonthescreen.

5.

Clickproceed.

6.

ClickClose.

Exercise2:SettingupOneStepAnalysis
Step1:Assigningthematerialandthicknesstothepart
1.

RightclickonCRDQSteel>Database...tochangethematerialselection.
Note:Auserdefinedmaterialcanalsobeaddedtothedatabasebyeditingthematerialfilehf.dat.

2.

Whenfinishedviewing/changingthematerialselection,clickClosetoclosethedialog.

3.

HighlightThickness:1byclickingonitonce.Doubleclickonthedigit1tomakeiteditableandchangethevalueto1.5.

Step2:Settingsymmetryconditions
1.

IntheOneSteptab,rightclickonSymmetry:No>Edit.

2.

Clickontheyellownodesbuttonandselectonplanefromtheextendedentityselectionmenu.

3.

Clickthetoggleswitchtoxaxis.

4.

Pickapointonthesymmetricplane,asshownbelow.

5.

Clickselectentities.

6.

UnderConstraintType,clicktheXradiobutton.

7.

Clicksize=andenter10.

8.

Clickupdate.

9.

Clickreturn.

constraintsalongthesymmetricedge

Step3:Settingthestampingdirection
1.

RightclickonStampingDirection:XandselectZ.
Note:StampingcanalsobedoneinanyofthethreeprincipalaxesoranarbitraryaxisinspacebyusingStampingDirectioninthe
Autotippanel.Usethestampingdirectionsubpaneltospecifythestampinginanarbitrarydirection.

IntheAutotippanel,usethevectorselectorswitchtoassignadirection.Ifthestampingdirectionofthepartisnotoneofthe
principalaxes,useN1,N2,N3optionandselect2nodesonthemodeltodefineadirection.

Clickset.

Step4:Selectingtheblankholder
Blankholderscanbedefinedastheupperandlowerholdingsurfacesthatcontrolmetalflowaroundashapetobeformedinadrawoperation.
Theysupplyarestrainingforceonthematerialduringthepressingprocess.
HyperFormallowsyoutodefinetheblankholderforceintwoways:onelementandonedge.Thecorrelationbetweenthemagnitudeandlevelof
theappliedforcesisalwaysavailable.Edgeblankholderforceapplicationallowsyoutorestrainanedgebyenablingautomaticselectionofall
nodesbetweentwouserdefinednodesalongafreeedgeofapart.
Youcandefinetheblankholderforceintwoways:tonnageforceorpressurelevel(high,mediumandlow).
Note:

Thepressurelevelisproportionaltotheareaofblankundertheblankholderaswellasthickness.Apressurelevelof2MPa,5MPaand
10MPafora1mmblankhasbeenchosenasareferenceforLow,Medium,andHigh(basedonpracticalexperience).Thetonnage
(metrictonunit)isequivalenttothepressuretimestheblankholderareanormalized/scaledbythethickness(1metricton=9810N).

1.

IntheOneSteptab,rightclickonBlankholders>New.Ifdesired,youcandoubleclickonBlankholder1tochangethename.

2.

RightclickonBlankholder1>Elements

3.

Clickelemsandselectonplane.

4.

Selectzaxisandpickanodeonthebinder(flatregion)forB(basenode).

5.

Clickproceed.

6.

Friction,TonnageandPressurelevelappearsbelowBlankholder1.DoubleclickonthevaluesforFrictionandTonnagetochangethe
values.

7.

RightclickonPressureLevel:andselectMedium.
NoticethattheTonnagechangesaccordingtotheselectedpressurelevel.

Step5:Creatingdrawbeads
Modelingtheexactdrawbeadgeometryrequiresalargenumberofelements,whichincreasesCPUtimedramatically.Apracticalapproachisto
useanequivalentdrawbeadmodelbyrepresentingthedrawbeadanalyticallyandprovidingaconstantdrawbeadrestrainingforceandclosure
force.
Usethecalculatesubpaneltodeterminetheclosureandrestrainingforcebasedondrawbeaddimensions.Therestrainingforceisthevalueof
theforce(perunitlength)appliedbythebeadintheplaneoftheblanksurface.Theclosureforceistheforce(perunitlength)requiredinthe
perpendiculardirectiontokeepthedrawbeadclosed.

1.

FromtheOneSteptab,rightclickonDrawbeads>New>Restrain.

2.

Picktwonodesonthepartasindicatedintheimagebelowtodefinethedrawbeads.

3.

ClickProceed.
Noticeamessageshows"Thedrawbeadsethasbeencreated."Alinerepresentingdrawbeadsiscreated.

4.

NoticethatDrawbead1iscreatedwithadefaultRestraintForceandPressureLevel.DoubleclickDrawbead1torenameit.

5.

RightclickonPressureLevel>Medium.NoticethatRestraintForcechangesbasedonthePressureLevelselection.

Step6:Tipping
1.

RightclickontheOneSteptabanywhereintheredboxasshownbelowandselectAutotip.

2.

Selecttheautotipradiobutton.

3.

Verifytheentityselectorissettocompsandselectthelvl1component.

4.

Verifythetoggleissettofullmodelandkeeptherestoftheoptionsasdefault.

5.

Clickcalcautotip.
Noticetheangletobetiltedisdisplayedontheheaderbaronthelefthandbottomcornerandthemagnitudeisdisplayedintheanglefield.

6.

Clickautotip.
ThisactionwilltiltthepartbyananglecalculatedbyHyperFormtoreducedrawdepthduringforming.

7.

Clickreturn.

Step7:Checkingforundercuts
1.

RightclickontheOneSteptabanywhereintheredboxasshownaboveandselectUndercutCheck.

2.

Clickontheyellowcompsbuttontohighlightit.

3.

Pickthepartfromthescreen.

4.

Clickoncheckundercut.
Noticethemessage0elementswithundercutdetected.Ifthereareundercutsinthemodelthenthefailedelementsarehighlightedonthe
screen.

5.

Clickreturn.

Step8:Checkingthemodelandrunningtheanalysis
1.

RightclickontheOneSteptabanywhereintheredboxasshownaboveandselectCheckModel.Amessageisdisplayedonthemessage
bar,statingModelchecked.

2.

RightclickontheOneSteptabandselectRun.

3.

Enteranamefortherun.
Thefeasibilitysolverlaunches,asshownbelow:
Note:Itisadvisedtoruntheanalysisintoaseparatefolder.

Exercise3:Postprocessing
Afterthesuccessfulcompletionoftherun,rightclickonthewhitespaceoftheOneSteptabtoseetheBlankShape,%thinningand
Formabilityoptions,whichwerenotavailablebeforerunningtheanalysis.

Rightclickandselectthedesiredresulttypeforpostprocessing.

Step1:BlankShape
1.

RightclickontheOneSteptabanywhereinthewhitespaceandselectBlankShape.

2.

UnderBlankShapeProfile:clickontheInitialradiobutton.Noticethattheinitialblankshapeisdisplayedonthescreen,asshown
below.

3.

Clickonexporttowriteoutanigesboundaryofthepredictedblankshapetothefolderwherefeasibilityanalysiswasrun.Thefilewillbe
namedas<filename>_blank.iges.

Exercise4:BlankFit
Step1:Fittingtheinitialblankshapeintodifferentconfigurations
1.

FromtheToolsmenu,clickonBlankFit.Thiswillbringuptheblankfitutility,asshownbelow:

2.

UsethePartdropdownmenutoselectthecomponentonwhichtheonestepanalysiswasrun.

3.

KeepthedefaultvaluesforDensityandCostperKg.

4.

UnderPLOTOPTIONS,clickonthecheckboxnextto%ThinningandFormability.Noticethat%ThinningandFormabilitybuttons
becomesactive.

5.

Rotatethemodeltoadesireddirectionandclickon%Thinning.Thiscontoursthemodelwith%Thinningresulttype.

6.

Leftclicktocapturetheimagetoincludeitinthereport.ArightclickwillabortthefunctionandreturntotheBlankFitmacro.Thisis
indicatedbytheimageontherighthandbottomcornerofthegraphicsarea

7.

UnderBLANKSHAPES,checkalltheboxes.

8.

ClickonBlankFit.
Thiswillfittheblankintotheselectedshapes.

9.

ClickonPublishReport.

ThiswillopenaHTMLreportwithhyperlinkstoblankshapesandresults,asshownbelow.

11.

ClickClose.

Exercise5:BlankNest
Step1:Nestingtheinitialblankshapeoncoilorsheet
1.

ClickTools>BlankNesting.

2.

Clickonelemsandselectdisplayedfromtheextendedentityselectormenu.

3.

Clickonthenestingbutton.AnewwindowcalledBlankNestingopenswhichallowsyoutonesttheblankindifferentconfigurations.

4.

RightclickanywhereontheblankshapeandselectDuplicate.Thiswillcreateaduplicateoftheexistingblankshape.

5.

RightclickanywhereonthebluescreenandselectAutonestingfromthemenu.Thiswillmakethebestfitofthe2shapesoftheblankon
asheet.

6.

ClickonFile>Export.

7.

EnteranameandclickonSave.Thissavesan.igesboundaryofthenestedsheet.

8.

SelectFile>ExittocloseBlankNesting.
Note:ThereisadetailedexplanationofalltheoptionsinBlankNestingintheHyperFormonlinehelp.

Exercise6:ReportGeneration
Step1:Publishingareportofthefeasibilityanalysisresults
1.

ClickTools>ReportGenerator.TheReportGeneratoropensupasshownbelow:

2.

ClickontheResultFile:filebrowsericonandselect<filename>.resinthefolderwhereyouhaverunthefeasibilityanalysis.
Note:Youmustrunfeasibilityanalysisinaseparatefolderwithnospacesinthepathandinthefoldername.

3.

ClickontheReportName:filebrowsericonandtypeanameforthereport.
Note:Thefolderandreportnamemustnothaveanyspacesinthefoldernameorfilename.

4.

CheckalltheboxesunderResultTypes.

5.

UnderExportMode,selectHTML.

6.

UnderExportOptions,selectJPEG.

7.

ClickonGenerate.ThiscreatesareportinthefolderselectedintheReportNamefield.Itincludesfolderscalled<filename>_data_dir
and<filename>.hml.

8.

OpenthefolderthatwasselectedforReportName.Openthefile<filename>.htmlinInternetExplorerorFirefox.Thisopensahtml
pagewithhyperlinkstotheselectedresulttypesandthecorrespondingimagewithcontour,asshownbelow:

9.

ClickClosetoclosethepanel.

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