The
functions enable users to:
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Setup tooling models that are either built up by using other DFE
functions or directly imported from outside eta/DYNAFORM;
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Setup tooling as following process types;
Crash form
Single-action draw
Double-action draw
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Setup draw beads;
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Setup blank material, symmetry conditions and other
constraints;
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Setup binder with either force-controlled or
displacement-controlled motion;
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Setup lancing operations;
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Setup adaptive mesh on blank;
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Option for blank gravity loading;
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Option for spring back simulation after forming simulation;
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Submit the setup model for simulation computation using ETA
exclusive INC solver. INC solver is the only choice of solvers when setup
and submit jobs using DFE/INC Solver
functions.
The main window
is activated by selecting INC Solver
from DFE pull-down menu as illustrated
in Figure
7.7.1.
Figure 7.7.1 DFE Menu |
Figure 7.7.2 INC Solver Main Page |
In Figure 7.7.2, red colored graphic symbols
indicate that none of the blank, draw beads and tools has been defined for the
simulation, typically so if the die face model is imported from outside eta/DYNAFORM,
instead of being created within DFE.
●
DEFINE TOOL
Click and
buttons to assign geometries to the tools. A
window will pop up and list related tasks as illustrated in Figure 7.7.3.
Figure 7.7.3 Define Tool
Display
Define Tool window (Figure 7.7.4) and enables users to select geometries using two approaches.
Display the Select Part dialog (Figure 7.7.5), allowing users to select parts
either from the part list, or on the screen if the parts are currently
displayed.
Allow users to assign all elements of the
parts selected from part list, or a number of elements selected from the
screen, to the designated piece of tool (Figure 7.7.6). Either way a new part will be
created, containing the selected elements. Please keep in mind that in this
function, elements are relocated, not copied, from one part to another.
After
successful execution of either Add or Add Elements, the part assigned to the
tool will appear under Include Part List
(Figure
7.7.7). Multiple parts can be added to
a piece of tool.
Disassociate the assigned part from the
designated tool. The removed parts will remain on the part list, and the added
elements, if any, stays within this part.
Shows only the selected part on the screen for
visual clarification, or shows the part if it is not currently displayed.
Figure 7.7.7 Tool Part List
Enable users to import element mesh into
eta/DYNAFORM database, usually in NASTRAN format.
Import surface and line data generated by
other CAD systems in various formats (Figure 7.7.8).
Figure 7.7.8 Import CAD Data
Provide same procedures and guide lines
detailed in section 5.3.4, Surface Mesh, of
eta/DYNAFORM User’s Manual.
Provide same procedures and guide lines
detailed in section 5.5, Model Check & Repair, of eta/DYNAFORM User’s Manual.
After
geometries have been assigned to the tools, the corresponding graphic symbols
will turn to green color (Figure 7.7.9).
Figure 7.7.9 Tool
If a die face model has been
created using DFE functions before
the DFE/INC Solver is activated, eta/DYNAFORM
memorizes the model as a component of the tool set. Upon opening, the DFE/INC Solver main page will look similar
to Figure 7.7.10, showing the draw type determined
by the tipping operation in DFE, and
the DFE-created die face as the
original lower tool.
Figure 7.7.10 DFE Tool
In such
cases, change of draw type is still allowed, as long as the draw tip is not
violated. In shown example, crash form and single-action draw are available by
choice, but not double-action draw. Switching of the original side of die face
is always available.
●
DEFINE DRAW BEAD
Define Draw
beads by clicking button, and follow the procedure detailed in section
10.3. Draw Beads. To effectively complete the definition of draw beads,
all the draw bead have to be attached to upper die for single-action draw, and
lower die for double-action draw.
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DEFINE BLANK
Click button to assign geometries to the blank. A
window will pop up as illustrated in Figure 7.7.11, and follow the procedure
detailed in section 8.2, Blank Generator.
Figure 7.7.11 Blank Generator
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BLANK PARAMETERS
Blank parameters are active for definition after
the blank is assigned geometry. Clicking leads to a material definition window (Figure 7.7.12).
Contain eta/DYNAFORM’s material database (Figure 7.7.13).
Figure 7.7.12 Define Material |
Figure 7.7.13 Material Library |
Activate a window page (Figure 7.7.14) to define a material model.
Figure 7.7.14 Material Parameters
As mentioned in the introduction
section that INC Solver applies
Hill’s or Barlat’s nonlinear anisotropic yielding criteria for material
modeling. This guide line is followed through all material definition processes
within this menu application, including selecting from material library,
importing material models from outside and creating new material models.
Provides functions used for defining blank
symmetry conditions. The default status, as the button reads, is without
symmetry definition. When clicked, it displays an interface window shown in Figure 7.7.15. The pull-down menu, Type, lists three
frequently used symmetry conditions used in sheet metal forming (Figure 7.7.16):
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XZ Symmetry: defines symmetry plane which parallels to XZ-Plane;
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YZ Symmetry: defines symmetry plane which parallels to YZ-Plane;
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Quarter Symmetry: defines a quarter symmetry
condition.
When either XZ or
YZ Symmetry is selected, a Y = 0 or X = 0 plane is
displayed on the screen, and all the blank nodes in the plane are highlighted (Figure
7.7.17). To relocate the
symmetry plane, click button and select one node that denotes where
the plane should be, the plane will shift to that node and all the nodes fall
into the plane will be highlighted. Enlarge the Tolerance to include
those nodes not collected by the plane due to model variations. Setup is
similar for Quarter Symmetry, except a center node needs to be selected
(Figure 7.7.18).
Figure 7.7.17 Half Symmetry
Figure 7.7.18 Quarter Symmetry
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TOOL CONTROL
Tool Control
section contains parameters relate to
tool travel speed (m/sec), binder support force (N) and lower binder travel (mm)
for single-action draw (Figure 7.7.19).
Figure 7.7.19 Tool Control
Tool Travel Velocity refers to travel speed of the
upper die/punch, default to 5000.
Binder Travel Velocity default value is 2000.
Upper Binder Force is available for double-action
draw, activate by checking on the box, then key in the value.
Lower Binder Force is available when draw type is
set to single-action draw, activate by checking on the box, then key in the
value.
Lower Binder Travel is also available when draw type
is set to single-action draw, activate by checking on the box, then key in the
value. The preferred amount of lower tool interference can be achieved by using
this feature.
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LANCING
Provide capabilities for users to integrate a
lancing operation into a forming simulation. The setup interface is shown in Figure 7.7.20.
Figure 7.7.20 Lancing
Click this button to select a lancing line
from screen. Repeat the operation if multiple lines are designed. With one
lancing line highlighted, input to the Position field to specify the
lancing position which is defined as the distance from the end of tool travel.
In multiple-line cases, lines with different lancing positions are allowed.
The button is used to delete the highlighted
lancing line from the list.
Click the button to accept the status of the Lancing
interface and dismiss the window.
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ADVANCED
Display more controlling parameters (Figure 7.7.21).
Figure 7.7.21 Advanced
Tool Offset refers to the offset distance applied to
develop the mating die face from its original. The default value is 110% of the
blank sheet metal thickness. The geometrical offset of the mesh model will not
be visualized on screen in this application. Instead, the offset is applied
during the computation and reflected in the Postprocess. The value of Tool Offset can be in the form of Percentage or Absolute value, switchable by checking the corresponding boxes.
Extra
clearance provides options for manual control of binder as well as punch/die
clearances that are otherwise defined by tool offset. For both input fields,
the default value
Closing allows users to decide the number of
snap-shot frames in the binder-closing simulation stage the output file will
contain. Default value is 5. The timings
that those snap shots are taken will be evenly distributed along the entire
closing stroke.
Drawing is similar to Closing if the Total Frames
option is checked. If the Distance from
End option is checked, users have the flexibility of specifying the moment
that each snap shot will be taken for all the snap shots ordered, in the form
of millimeters to the end of draw. Default values are provided.
Reset all parameters back to their default
values.
Confirm all current entries and exits the
page.
Dismiss the window, keeping values of all
parameters prior to modification.
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APPLY
Click this button in the INC Solver main
page to position the tools and blank after their definitions are complete. The
setup creates ample distance between upper and lower tools, providing
sufficient room for the possible blank deformation under gravity loading. Such
arrangement is due to the fact that in this simulation application, the gravity
loading and subsequent forming stage are proceed as a seamless process. The gap
that appears on the screen will be adjusted by the solver, correspondent to
whether the gravity loading is included. The button also performs an updating
function, whenever a setup-related parameter is modified. In other words, the Preview
and Submit Job can be executed only if this button is inactive.
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UNDO
When clicked, it will discard the
tool-positioning result.
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PREVIEW
The function animates the tooling motion, and
follows the procedure detailed in section 10.14, Animate.
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SUBMIT JOB
Enable users to include Gravity Load and
Spring Back options prior to submitting job (Figure 7.7.22).
Figure 7.7.22 Submit Job
Gravity and Spring
Back simulations can be included by toggling
on the checkbox of corresponding box. Adaptive
level, from none up to 6, can be
selected from the pull-down menu. Clicking Submit
button will start computation or put the job onto the waiting list at Job
Submitter. Cancel will return to the INC solver main page.
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EXIT
The button dismisses the INC Solver page, retaining all the setup parameters. Note: If close eta/DYNAFORM database is terminated without
saving, all the setting will be lost.
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HELP
The button display
all help documents, including Keyword, Best Practice and User Manual (Figure 7.7.23), open by clicking related button.
Figure 7.7.23 Help