This dialog enables the user to define a new simulation prior to displaying the Auto Setup interface. First, select AUTOSETUP from the SETUP menu. If Auto Setup is defined in the existing database, the program will automatically display the Auto Setup interface. Otherwise, the program will automatically display the New Simulation window illustrated in Figure 8.2.2. The user must define the setting in New Simulation window.
NOTE: The user is only allowed to set one Auto Setup project in each database.
Figure 8.2.2 New Simulation window
There are two simulation types supported in the Auto Setup. One is sheet forming, which includes sheet forming and sheet hydroforming. The other one is tubular hydroforming.
At the beginning of each new setup, the user shall key in the desired blank thickness. This value will be automatically set in Blank page. The user may modify the blank thickness in Blank page. Default blank thickness is 1.0 (mm).
As shown in Figure 8.2.3, the Auto Setup includes 6 ordinary process templates. The Trimming and Superplastic templates are added in eta/DYNAFORM 5.6.
Figure 8.2.3 Process
GRAVITY: gravity loading simulation
CRASH FORM: forming process using upper and lower tools.
SINGLE ACTION: air draw or inverted toggle draw process using die, punch and binder.
DOUBLE ACTION: toggle draw process using die, punch, upper and lower binders.
TRIPLE ACTION: forming process using multiple pieces of tooling.
SPRINGBACK: springback analysis.
TRIMMING: trimming simulation.
SUPERPLASTIC FORMING: superplastic forming simulation
In this field, the user chooses to perform stamping simulation using either CONTACT OFFSET algorithm or physical tool geometry. The user may turn on the radio button of either DIE (upper die) or PUNCH (lower die) option if he/she selected the CONTACT OFFSET algorithm. As illustrated in Figure 8.2.4a, the contact interfaces of both punch and binder are offset by (2 x blank thickness) + gap if the DIE option is chosen. Similarly, the contact interfaces of die is offset by (2 x blank thickness) + gap if the PUNCH option is chosen, as illustrated in Figure 8.2.4b.
Note: The geometry of punch and binder are duplicated from the die geometry if CONTACT OFFSET algorithm is adopted in stamping simulation.
a) Using DIE geometry as reference for contact offset
b) Using PUNCH geometry as reference for contact offset
c) Using both DIE & PUNCH physical geometry
Figure 8.2.4 Blank Reference Surface
If the user chooses to perform the stamping simulation using physical tool geometry, he/she should turn on the radio button of DIE&PUNCH illustrated in Figure 8.2.2. It is recommended to perform stamping simulation using physical tool geometry if springback is primary concern.