DEFINE

This function allows the user to read in CAD model or finite element model. If the imported CAD data is a solid model with thickness information, the user can use MIDDLE SURFACE or SEPARATE SURFACE function to generate the desired surfaces. Then use UNFOLD FLANGE function to unfold the flange on the generated surfaces. In addition, the user can also use SURFACE EDIT or SURFACE SPLIT function to add the flange to a new part. Once the user clicks on the ADD button in FLANGE group, a dialog box as shown in Figure 6.1.2 appears. Click on SURFACE(S) to select flange surfaces, and then enter a part name in the TO PART field, as shown in Figure 6.1.3. Click APPLY to create a new flange part. The user can also click  button to add the selected flange surfaces to another existing part. At the same time, the program will automatically add this part to the flange list, as shown in Figure 6.1.4. Besides, the user can also use RENAME and REMOVE button in FLANGE group to rename the flange part or delete the flange part.

      

Figure 6.1.2  Select Flange Suface                  Figure 6.1.3  Create Flange Part

define

Figure 6.1.4  Add Flange Part

In the mean time, the user can click on ADD button in TOOL group to define some parts as punch and perform SURFACE MESH, INNER FILL, OUTER SMOOTH or SIDE-STEP on the defined punch. In addition, the user can also click on RENAME and REMOVE buttons to rename the punch part and delete the punch part. After defining the punch, the font color of DEFINE will change from red to black.

 

Details about functions in the interface are described below.

 

6.1.1.1  IMPORT

This function allows the user to read in CAD or finite element model data into active database. Please refer to Section 3.6 for detailed information about the Import function.

 

6.1.1.2  MIDDLE SURFACE

This function allows user to create the mid surface from a solid part. For more information please refer to the Section 5.2.7.

 

6.1.1.3  SEPARATE SURFACE

This function is used to separate the top and bottom surface layers of sheet metal parts with the thickness information. For more information please refer to the Section 5.2.8.

 

6.1.1.4  UNFOLD FLANGE

This function unfolds flanges on a product so the user can create an addendum with a developed product trim line.

 

·         Once the function is selected, eta/DYNAFORM opens the SELECTED SURFACE dialog box to select flange surfaces to be unfolded.  Refer to Figure 6.1.5 for typical surfaces with the defined flange highlighted.

Figure 6.1.5 Select Flange Surface

·         After selecting surfaces, the DFE module will determine and highlight the unfold line and the boundary line. As shown in Figure 6.1.6, the bold line is the unfold line, and the other is the boundary line of the base surface and unfolded surface.  eta/DYNAFORM displays a SELECT OPTION dialog box as illustrated in Figure 6.1.7. The user has to select an option to continue operation.

Figure 6.1.6 Unfold Line and Boundary Line

Figure 6.1.7 Select Option dialog box

·         If the unfold line and boundary line are correct, select ACCEPT to continue. The program will unfold the selected surfaces along the unfold line and continue to the next step.

 

If the unfold line is not correct, select RETRY.  eta/DYNAFORM will use a different method to find the desired unfold line and boundary line. If ADJUST GAP TOLERANCE is selected, the dialog box as illustrated in Figure 6.1.8 is displayed to allow the user to change the gap tolerance between surfaces.

Figure 6.1.8 Input Gap dialog box

The default gap tolerance is 2.5.  If there are small surfaces in the part, a smaller gap tolerance should be used. If SELECT BASE SURFS is selected, eta/DYNAFORM allows the user to select surfaces as the base surfaces.  A base surface is a surface that connects the flange surfaces along the unfold line.

 

Figure 6.1.9 Input Bent Angle dialog box

 

The unfolded surfaces are automatically stored in a new part named UNFOLDED.

 

Figure 6.1.10 Unfolded Flange

Figure 6.1.11 Control Keys dialog box

 

SMOOTH EDGE

This function allows the user to smooth the edge of unfolded surfaces. eta/DYNAFORM will request the user to select the starting and ending points on the edge of the unfolded flange. The smoothed edge will be highlighted as shown in Figure 6.1.12.  The CONTROL KEYS dialog box as illustrated in Figure 6.1.13 is displayed. The user has to select the next step from the options provided in the dialog box.

 

Figure 6.1.12 Smooth Edge

Figure 6.1.13 Control Keys dialog box

 

FINISH SMOOTH – Completes the smooth edge operation.

SMOOTH AGAINPerforms the smooth edge operation again.

UNDOUndoes the last smooth operation.

 

DELETE ORIGINAL FLANGES

The original flange surfaces will be removed from the database.

 

UNFOLD ANOTHER FLANGE

Continues to unfold another flange by repeating the steps previously mentioned.

 

6.1.1.5  SURFACE EDIT

This function allows the user to edit surface by editing the control points on surface, as shown in Figure 6.1.14.

Figure 6.1.14  Surface Edit dialog box

After clicking on SELECT SURFACE button, the user can use cursor to select a surface on which the control mesh will be highlighted, as shown in Figure 6.1.15. Then the user can click DEFINE DIRECTION button to display the Define Vector dialog box. Please refer to Section 5.1.4 Shortest Curve for detailed operation.

Figure 6.1.15  Display Surface Control Mesh

 

Once the surface morphing direction is defined, the user can select one or multiple (SHIFT + left mouse button) control points by cursor and then drag one of the selected control points to edit surface, as shown in Figure 6.1.16.

 

 

(a)                                   (b)

Figure 6.1.16  Edit Surface

Note: The edited surface must be an non-trim surfaces.

 

6.1.1.6  SURFACE SPLIT

This function allows the user to split the selected surface into two surfaces at the specified line. Refer to Section 5.2.11 for detailed description of surface split.

 

6.1.1.7  MESH TOOL

This function is similar to the SURFACE MESH function as described in the Section 5.3.4, SURFACE MESH.

 

6.1.1.8  MODEL CHECK /REPAIR

All functions in the MODEL CHECK /REPAIR dialog box are described in Sections 5.5. Please refer to the section for a detailed description of these functions.

 

6.1.1.9  TOPOLOGY REPAIR

This function allows the user to auto repair topological structure that is not connected. After selecting the option, the program will pop up the dialog box in which the user can select the part to repair. The user can compare the original topological structure with the repaired as shown Figure 6.1.17.

 a) Original topology                             b) Repaired topology

Figure 6.1.17 Auto topology repair

 

6.1.1.10   OUTER SMOOTH outer_smooth

The functions provided in the OUTER SMOOTH dialog box are used to smooth the outer boundary of the selected part. As illustrated in Figure 6.1.18, there are four functions in the dialog box (ROLLER, MORPHING, CORNER SMOOTH, EXPAND).

Figure 6.1.18  Outer Smooth

Before outer smooth, the user must specify a part by clicking on SELECT PART button.

 

l  ROLLER

    This function allows the user to roll a cylinder with a defined radius along the boundary and fill the gaps between the part boundary and the cylinder.  Once this function is selected, a dialog box as illustrated in Figure 6.1.19 is displayed.  The default radius of the cylinder is 300 (mm) in the ROLL RADIUS input field.

Figure 6.1.19  Roller dialog box

 

1.       After the desired radius is entered, click on the CREATE BOUNDARY button to show the new boundary line with the cylinder rolled along the part boundary.  If the result is acceptable, click on the FILL BOUNDARY button to fill the gap with elements and new surface. A new part will be created to include the elements and surfaces. The part will be automatically assigned as the DIE.

2.       The UNDO function is used to remove the filled mesh in the gap and allow the user to go back to the original part. Figure 6.1.20 illustrates the result of a typical roller operation.

roller1    roller2

Figure 6.1.20  An illustration of a roller operation

3.       Click on the CLOSE button to exit the function.

 

The LOCAL option allows the user to roll a cylinder with a defined radius along a selected boundary.  eta/DYNAFORM will fill the gap between the part boundary and the cylinder surface to smooth the local boundary.

Click on the ROLLER button and select the LOCAL option. The default radius of the cylinder is set to 300 (mm) in the ROLL RADIUS input field. The user can input any desired PART NAME and ROLL RADIUS.

 

  1. After the desired radius is entered, click on the CREATE BOUNDARY button to show the highlighted boundary line. eta/DYNAFORM requests the user to select two points on the boundary line (first and second) to identify the area to be rolled. Upon completing the point selection, the user needs to press the middle mouse button to continue the operation.

 

  1. Once the middle mouse button is clicked, a smoother, virtual boundary will be highlighted over the original boundary. If the result is acceptable, click on the FILL BOUNDARY button to fill the gap. eta/DYNAFORM will create a new part with the given name to include the filled mesh and surfaces. In addition, this part will be automatically assigned as DIE. Fig. 6.1.21 illustrates the result of a typical roller operation using the LOCAL option.

HyperSnapClipImage

Fig. 6.1.21 An illustration of Outer Smooth/Roller using Local option

 

l  MORPHING

This function allows the user to locally modify the part mesh by morphing the boundary line of the part. Figure 6.1.22 illustrates dialog box of the MORPHING function.

Figure 6.1.22 Morphing dialog box

 

1.       Click on the MORPHING BOUNDARY button to highlight the boundary of the die. Eta/DYNAFORM requests the user to select two points on the part boundary to define a morphing region. Figure 6.1.23 illustrates the selected region on the part boundary for morphing operation.

 

Figure 6.1.23 Select Morphing Boundary

2.       After two points are selected, the CURVE EDIT dialog box as illustrated in Figure 6.1.24 is displayed. About the detailed description of Curve Edit function, the user can refer to the Section 5.1.15.

 

Figure 6.1.24  Curve Edit dialog box

 

3.       Click on the FILL BOUNDARY button to fill elements between the original boundary and the smoothed boundary.  The result from a typical morphing operation is illustrated in Figure 6.1.25.

 

    

Figure 6.1.25 Morphing Result

 

4.       The UNDO button is used to remove the elements from the gap, allowing the user to return to the original boundary and keep the newly created part in IGS_SMH.  PART NAME enables the user to assign a name to the part; it will be automatically assigned as TOOL.

5.       Click on the EXIT button to exit the function. The generated elements, nodes or surfaces, etc. will be automatically saved in a part named IGS_SMH. The user can modify the name of this part and the generated part will be automatically added to the punch.

 

l  CORNER SMOOTH

This function allows the user to smooth sharp corners on a part using a defined radius. eta/DYNAFORM will generate a set of elements in circular shape with the defined radius around the selected point.

 

When this function is selected, the dialog box as illustrated in Figure 6.1.26 is displayed.  The default corner radius is 30 (mm) as displayed in the input field of CORNER RADIUS.

Figure 6.1.26 Corner Smooth dialog box

 

1.       After entering the desired corner radius, click on the CORNER SMOOTH button to highlight the boundary line of the part such as illustrated in Figure 6.1.27.

Figure 6.1.27  Sharp Corner

 

2.       The user selects a node on the boundary for the corner smooth operation.

3.       After a node is selected at a sharp corner, eta/DYNAFORM will generate a set of elements around the part boundary to create a circular shape to smooth the edge.  Figure 6.1.28 illustrates a typical result of a corner smooth operation.

 

Figure 6.1.28 Corner Smooth

 

4.       The UNDO button is used to remove the elements from the smoothed corner and allowing the user to obtain the original boundary.

5.       Click on the CLOSE button to exit the function.

 

 

 

l  EXPAND

The EXPAND function is used to extend the part boundary with elements.  When this function is selected, dialog box as illustrated in Figure 6.1.29 is displayed.  The value in the input field of EXTENSION is the default extension value for the active part.  The user can type in any positive value.

Figure 6.1.29  Boundary Expand dialog box

 

1.       Click on the BOUNDARY EXPAND button to highlight the boundary of extension as illustrated in Figure 6.1.30a.  The default extension value is calculated from the average element size.  The user can input other value following by clicking the BOUNDARY EXPAND button once again to modify the default value.

 

2.       Select the MORPH BOUNDARY button to morph the boundary line. Refer to Section 5.1.15 LINE MORPHING for description of this function.

 

3.       The FLATTEN BOUNDARY SEGMENT function allows the user to flatten line segment between two selected points on the boundary line.

 

a) Extended boundary                             b) Filling extended boundary

Figure 6.1.30 An illustration of the Boundary Expand operation

 

4.       When the morphed boundary is accepted, click on the FILL BOUNDARY button to generate the mesh between the original boundary and the extension boundary.  An illustration of extended boundary with filled elements is illustrated in Figure 6.1.30b.

 

5.       The SMOOTH CORNER function allows the user to smooth a selected a sharp corner.

 

NOTE:  A sharp angle is determined by two adjacent boundary elements when the angle between two boundary edges is greater than 30º.

 

Click on the UNDO button to remove the generated mesh and exit the function.

 

 

 

6.1.1.11   INNER FILL

The INNER FILL function is used to fill holes and missing geometry on outer boundary of the products such as windows, wheel houses, tail light lamps, access holes, bolt holes, etc.  There are four functions available in INNER FILL dialog box as illustrated in Figure 6.1.31. These functions are:

1.       Auto Fill

2.       Hole Fill

3.       Curve Fill

4.       Polygon Fill

Figure 6.1.31 Inner Fill dialog box

Create Surface

This option allows user to decide if surfaces are generated upon completion of the inner fill operation.

 

Use Reference Line

It is an advanced option. For filling complicated surface, the user can create some reference curves to fill the holes.

 

Keep Tangent

This option enables the user to keep tangency between the existed surfaces and surfaces generated by fill operation. Figure 6.1.22 illustrates the surface generated with and without tangency option.

 

Figure 6.1.32 Toggle on/off Keep Tangent option

 

ADVANCED

The advanced option includes some auxiliary functions that are mainly applied on single hole fill, as shown in Figure 6.1.33. These functions are used for generation of reference lines, removal of curves, surfaces and elements. Detailed description about these functions refers to Section 5.2.11 Surface Split.

 

Figure 6.1.33 Advanced Option

 

DELETE

This option enables the user to remove the selected entities from the database.

 

l  AUTO FILL

 

After selecting this button and clicking APPLY, the program will automatically find all the inner holes and highlight their boundaries, as shown in Figure 6.1.34.

 

Figure 6.1.34  Before Inner Fill

 

Simultaneously, eta/DYNAFORM prompts:

 

CLICK ON INNER BOUNDARYS TO DE-SELECT

MIDDLE BUTTON – DONE, RIGHT BUTTON - CANCEL

 

If there are holes which do not need to be filled, the user can select them by mouse cursor and click on the middle mouse button to confirm. The result is shown in Figure 6.2.35.

Figure 6.1.35  After Inner Fill

 

UNDO

If the user is not satisfied with the result of Auto Fill, he/she can select UNDO button to cancel this result.

 

EXIT

Exit the Inner Fill interface.

 

l  HOLE FILL

This function allows the user to fill holes individually. Once this function is selected, the boundary of the inner hole on the current screen is highlighted. Then, the program prompts the user to select an inner boundary to be filled by using the left mouse button. After an inner boundary is selected, the program will automatically fill the hole, as illustrated in Figure 6.1.36.

Figure 6.1.36 Boundary Lines of Inner Holes

 

If Hole Fill function is selected, User Reference Line option is activated for the user to create some reference lines for hole filling, as illustrated in Figure 6.1.37.

Figure 6.1.37 Filled Mesh within a Closed Curve

 

l  CURVE FILL

This function allows the user to fill an open or cut-out area. Figure 6.1.38 illustrates an example of Curve Fill operation using a spline curve to close the cut-out area.

Figure 6.1.38 Filled Mesh with Open Curve

 

SELECT LINE

This option allows the user to select and define an existing line as the outer boundary of the open curve. After a line is selected, the SELECT NODES dialog box is displayed. The following message is printed in the message prompt window:

 

SELECT TWO NODES TO SPLIT THE LINE, OR PICK OK TO USE THE ENTIRE LINE

 

After selecting two nodes, the line segment between the selected nodes will be used as the boundary to close the open curve.

 

CREATE LINE

This option allows the user to create a line as the outer boundary to close the open curve for filling.  After a line is created, the SELECT NODES dialog box is displayed. The following message is printed in the message prompt window:

 

SELECT TWO NODES TO SPLIT THE LINE, OR PICK OK TO USE THE ENTIRE LINE

 

After selecting two nodes, the line segment between the selected nodes will be used to close the open curve.

 

CREATE SPLINE

Allow the user to create a spline curve as the outer boundary for fill mesh.  After a spline is created, the SELECT NODES dialog box is displayed. The following message is printed in the message prompt window:

 

SELECT TWO NODES TO SPLIT THE LINE, OR PICK OK TO USE THE ENTIRE LINE

 

After selecting two nodes, the spline segment between the two points will be used.

 

l  POLYGON FILL

This function allows the user to select a set of nodes as the boundary edge to create a mesh to fill the boundary. After function is selected, the SELECT NODES dialog box is displayed. The following message is printed in the message prompt window:

 

SELECT A SET OF NODES CONSECUTIVELY AS BOUNDARY EDGE

 

After a set of nodes is selected, eta/DYNAFORM will generate a set of elements to fill the inner boundary.

 

6.1.1.12   SIDE-STEP

This function allows the user to extend part boundary and provide side-step features. The dialog box is illustrated in Figure 6.1.39.

Figure 6.1.39  Sidestep dialog box

l  SELECT REGION

This function allows the user to select the desired region. After clicking on this button, the program will highlight the part boundary. The user can first select two boundary points by cursor to define the region at the bottom of Sidestep, and then select another two boundary points to define the region at the top of Sidestep. The program will automatically generate the outline of the region, as shown in Figure 6.1.40.

Figure 6.1.40  Select Region

 

l  BOUNDARY POINT EDIT

This function allows the user to edit boundary point. After region is selected, this button is activated. The user can click on this button and move boundary point by cursor to edit the region.

 

l  CONTROL LINES

This function allows the user to list the control lines. In Control Lines list, the user can select the control lines to be edited.

 

l  LINE DIRECTION

This function allows the user to define line direction. The user can select DEFAULT or USER DEFINE. Once this option is selected, the program will pop up a Define Vector dialog box. Please refer to Section 5.1.4 Shortest Curve for detailed operation of this dialog box.

 

l  LENGTH

This function allows the user to edit length of control lines. The user can select the desired control lines in Control Lines list and then drag slider to the desired length.

 

l  RADIUS

This function allows the user to edit radius of control lines. The user can select the desired control lines in Control Lines list and then drag slider to the desired radius.

 

After completion of editing, click APPLY to generate Sidestep, as shown in Figure 6.1.41.

Figure 6.1.41  Generated Sidestep

 

6.1.1.13   FILLET MESH fillet

The FILLET MESH function is used to generate fillet elements at the sharp corners of a part.  This function requires a relatively clean mesh without overlap elements or interior gaps, in additional to consistent element normals.  The FILLET MESH dialog box as illustrated in Figure 6.1.42, provides options to locate and fillet sharp corners.

 

mesh

Figure 6.1.42  Fillet mesh dialog box

 

The following steps are required to generate the fillet mesh:

 

          FEATURE ANGLE 

1. Enter the angle criteria (the default is 45º).

2. Click the FIND FEATURE LINES button to seek the feature lines where the angle is larger than or equal to the angle criteria. The program will highlight all features lines that meet the criteria.

 

          FILLET ELEMENTS

1.       Key in input field of FILLET RADIUS to define fillet radius for all feature edges.

2.       If SELECT FEATURE LINE option is selected, eta/DYNAFORM will display the SELECT NODE dialog box for the user to select two or three nodes on the feature line.  If two nodes are selected on a two-face feature line, eta/DYNAFORM will display a dialog box as shown in Figure 6.1.45a. If three nodes on a three-face feature line are selected, eta/DYNAFORM will display a dialog box as illustrated in Figure 6.1.46a.

Figure 6.1.43  Find feature lines

 

3.       ALL FEATURE LINES

When ALL FEATURE LINES function is selected, all feature lines will be filleted with the same radius.  Press OK button on the PARAMETERS dialog box to generate the fillet mesh.  The FILLET function supports different radii and automatically smooth the elements.

Figure 6.1.44  Fillet with All Feature Lines

 

   

Figure 6.1.45a  Element Fillet                Figure 6.1.45b  Select feature line

 

 

Figure 6.1.45c  Element Fillet Result

 

          

Figure 6.1.46a  Element Fillet               Figure 6.1.46b  Select Feature Line

 

Figure 6.1 46c  Element Fillet Result