eta/DYNAFORM is an LS-DYNA-based
sheet metal
forming simulation solution package developed by Engineering Technology
Associates, Inc. The specialty CAE software combines
the sheet forming analysis power of LS-DYNA Versions 971 with the streamlined
pre- and post-processor functions. These analysis codes and interactive
functions are uniquely integrated to service the sheet metal forming industry
in tooling design and development, which helps designers reduce tooling
development time and tryout lead-time.With its
superior usability and intelligent tools, eta/DYNAFORM can easily solve
all kinds of sheet forming problems. The program also
maximizes traditional CAE techniques to reduce prototyping costs and
lead time for product development.
eta/DYNAFORM’s
analysis engine is LS-DYNA, which is developed and currently supported by the
Livermore Software Technology Corporation (LSTC) of
The
bottleneck of the metal forming development cycle is the hard tooling design
lead-time. The eta/DYNAFORM CAE approach simulates this tooling process and
thereby reduces the tooling tryout time and the associated cost for producing
high quality stamped parts. eta/DYNAFORM effectively simulates the four major
design concerns in the tooling process: Binder Wrap, Draw Die, Springback, and Multiple Stage Tooling. These simulations enable
engineers to conduct feasibility studies of a product design early in the
design cycle.
eta/DYNAFORM
features well-defined tooling surface data to predict the performance of a
stamping for areas such as Tearing, Wrinkling, and Thinning, in addition to predicting Skid Mark and Springback effects.
Multi-Platform:
eta/DYNAFORM
is available for all UNIX workstation platforms including DEC(Alpha), HP, IBM,
SUN, and SGI. It is available on PC for Windows 2000 operating systems and
above. For Linux, the Red Hat Enterprise Linux 5 and above is supported.
SPECIAL FEATURES OF ETA/DYNAFORM 5.8 INCLUDE:
A process oriented module- AUTOSETUP
The AutoSetup module consists of Preparation,
Sheet Forming, Tube Forming, Rotary
Bending, Roller Hemming and Superplastic Forming. The Preparation
module is used to prepare the necessary tools for the
analysis model; Sheet Forming completes various setups
for blank forming analysis, including laser tailor-welded blank, laminated
sheet, thermal forming, hydroforming and multi-stage forming; Tube Forming sets up hydroforming for tube; Rotary Bending performs multi-stage bending simulation on
tube; Roller Hemming sets up simulation for
robot roller hemming process; Superplastic
Forming provides a quick setup interface for superplastic forming simulation.
The
multi-stage simulation option in the sheet forming module provides a complete
set of solutions for engineering problems. It enables the user to complete
multiple stage setups fully within the AutoSetup interface and submit for
calculation. Users will find the user-friendly interface, concise design style
and comprehensive functions in the multi-stage simulation refreshing. This module is process oriented
and enables users to easily set up all types of simulation. The sheet forming module combines
the merits of user setup power and quick and easy setup. It provides a perfect
combination of function and operation while avoiding the traditional
disadvantages of difficulty in usage and single quick setting function.
In the sheet forming module, the user can define stamping
direction, welded
blank simulation, hydroforming simulation, multi-stage simulation and trimming.
In addition, thermal forming and cooling simulations are also added to sheet forming.
The enhanced material library in AutoSetup module allows the user to add the
standard material library for corporations to the program interface for easier
selection of common used materials.
Rotary bending is a setup module for tube
bending analysis and it is completely in accordance with the practical process.
With the user-friendly interface, the user may define a bending axis for
arbitrary axis bending, and perform multi-step rotary bending simulation and
tubular springback simulation. This module is also equipped with functional
modeling for the user to directly create tube and the meshes of various tools
for new simulation, which may greatly reduce the setup time and improve
modeling efficiency.
The tube
forming module is used to set the internal high pressure for forming. Multiple stage analysis including springback
can be performed. The user can adopt the hydraulic mechanism by Pressure and
Volume, and the user can also specify a detailed pressure curve. The settings for
tube forming are similar to blank hydro forming, which makes it easier to grasp
the operating process.
Roller hemming is a
setup module for rolling analysis. With the user-friendly interface the user can define or select a line as its
orbit to make the roller move along specified path.
The
superplastic forming module is used to analyze capabilities of sheet forming in
superplastic temperature range and under specified pressure. It provides a complete
scheme for superplastic forming.
The major improvements include:
·
A
new Tube Bending (Rotary Bending) application has been added to perform
multi-stage tube bending (rotary draw bending) simulations.
·
Added
new “Roller Hemming” GUI in AutoSetup to allow for hemming of
separate blank mesh geometries.
·
Added
a new “Blank Generator” GUI to create and prepare initial blank
geometry and edit blank mesh.
·
Added
a new “Tool Preparation” GUI in AutoSetup, providing access to a
comprehensive set of tools to generate and modify line and surface geometry, as
well as generate and modify mesh.
·
Sharing
of tools between forming operations in multi-stage simulations has been
improved, automatically creating a copy of mesh already assigned as a tool.
·
Activated
an option to allow user to set and customize the contact between tools.
·
Expanded
MAT_24 (*MAT_PIECEWISE_LINEAR_PLASTICITY) parameters.
·
Added
an option to define constraints with (xyz) coordinates in springback stage,
which map to appropriate nodal locations.
·
Added
an option to define trim seed location with (xyz) coordinates, which maps to
the appropriate nodal location.
·
While
previewing tooling animation, an arrow will be shown indicating the direction
of each applied force, and colored the same as the tool applied to.
·
Supports
the import of Unicode curve file format.
·
Supports
setting initial reference positioning gap between tools as well as between
tools and blank.
·
Definition
of tooling geometry is supported in springback simulations.
·
Improved
functionality of the Lancing trim option.
·
Added
annealing stage, defined by an annealing factor.
Blank Generator
This function enables the user to create blank mesh by adding blank part, importing blank element, meshing surface and blank outline. The major improvements include:
·
Allow user to add blank mesh part to part list and assign as the
current blank.
·
Allow user to mesh surface and assign as the current blank.
·
Allow user to import blank mesh and assign as the current blank.
·
Allow user to create blank outline and mesh blank.
·
Provide the related tools for checking and modifying blank mesh.
Updated Drawbead function
This module contains Line Bead and Geometry Bead, which can be easily converted to each other. The user may define the drawbead curve through selection, import and creation and also define the lock force of a drawbead by using four methods. One of the methods is to calculate drawbead force according to section shape, which is very convenient, and the defined section shape is relating to the geometry bead. The line bead can be imported and exported. All operations in drawbead generation, including property definition, modification and project can be easily performed without advanced training. Geometry bead is utilized to create geometry bead mesh according to the defined section shape. It automatically reads in the information of line bead for the creation of geometry mesh model. The user may also import curve directly to define geometry bead. High quality surfaces will also be generated when generating mesh model.
The major improvements include:
·
Added
the uplift force calculation in restraining force with theoretical equation.
·
Add
force calibrator (DYNA) to calculate its restraining force by simulating method to get the drawbead restraining curve,
uplift force curve, plastic strain curve and dimension relation curve.
·
Allow
user to import/export calculation results by simulating method.
·
Added
the show of force value and force percentage. The user can shift between force
value and force percentage in a graphic region.
SCP module
Springback Compensation Process (SCP) is used for die compensation of sprung sheet metal parts. Springback is known to be a crucial issue for the sheet stamping industry. The springback compensation based on finite element technology is utilized to alleviate the severity of springback phenomena. SCP is used to modify the original die face in a direction opposite the springback and by a scaled magnitude generated from the springback simulation to ensure part dimensions fall within the tolerance of the intended part design after springback. The SCP module in eta/DYNAFORM also provides some practical tools for the user to repair the compensated die face and improve the efficiency for die face design.
Improved functionality of DFE module
Compared to the previous version, many
functions in the DFE module of eta/DYNAFORM 5.8 are improved to satisfy user
needs for friendly and functional operation. New functions including Element Morph, Embossment and Trim Check are added. The user can quickly import the product
and complete the entire process of die face design. The
major improvements include:
·
Functional Tool Preparation for DFE. The check/modification functions
of Line, Surface, Element and Node are combined with the Model Check/Repair
functions in an integrated preparation interface for DFE, providing a more
convenient and streamlined method for user modification of surface and mesh
data, improving process flow.
·
The Tipping Result record has been augmented to allow the user to
edit the result values.
·
The
editing function for Binder control lines has been improved. The user can copy the Die part section line
from the 2D section window, and assign the Binder section line to match.
·
The “Part on binder” tab has an
added Fit Side Step option to extend Side Step mesh to meet the binder mesh.
·
The
“Addendum” GUI has been redesigned to simplify the input of profile parameters.
Using the improved and optimized addendum
algorithm, the user can design addendum with various shapes.
·
The
DFE Modification tool set has had a element Morph function added, enabling the
user to generate morphed elements within defined regional shapes by adding
control curves and/or control points.
·
A
new “Embossment” function has been added, allowing the user to create an
embossment (a special bead) on existing mesh by specifying radius, depth and
wall angle parameters.
·
A
Trim Check function has been added to the DFE menu, which enables the user to
analyze trim angle, shear angle and scrap size by defining trim line, blank
line and cut line.
INC Solver
Enhanced BSE module
In eta/DYNAFORM
5.8, quick unfold, Batch MSTEP and Batch BSE modules are added for the user to
perform quick batch operations on multiple parts and output reports. MSTEP is
improved to estimate forming capabilities during the part design stage while
obtaining the outline. The trim line module is improved to obtain the trim line
of complicated parts quickly. The nesting function has also been improved and
optimized to satisfy the need forfriendly and functional operation. For nesting
of complicated parts, the nesting result yields higher material utilization
rate and more practical nesting pattern.
In eta/DYNAFORM
5.8, the BSE module is greatly improved with its concise and easy operating
user interface. In addition, improvements and enhancement are added to satisfy users’
needs. The user can import the part model to evaluate
outline characteristics and calculate nesting results. The
major improvements include:
·
Improved
BSE design procedures and integrated portions of the original functions from
previous releases. This function enables the user to operate easily and perform
part design with their received data.
·
Improved
the preparation interface. The functions in the preparation interface are newly
integrated and many functions are added in accordance with process flow.
·
Improved
MSTEP to estimate forming capabilities during the part design stage while
obtaining the outline.
·
Improved
the outline interface so that the use can create and edit an outline by
integrating useful preprocessing functions.
· Improved the nesting function to optimize the nesting result with its friendly user interface and easy operation.
Die System Analysis(DSA)
The Die
System Analysis module provides a set of solutions for solving practical
problems encountered in part production. Finite Element Analysis is utilized to
efficiently predict possible problems in a die design and within the die
production line to optimize the design of the die structure and the production
line. This could greatly reduce try-out time and lower the development cost of
new products. The Die System Analysis module includes Die Structural Integrity
(DSI), Scrap Shedding Removal (SSR) and Sheet Metal Transferring and Handling
(SMTH). In all the analyses of the DSA module, the program provides simple
graphic interfaces to guide the user through execution of complicated
preparation and simulation processes.
Enhanced Pre-processor functions
·
Improved
the “Dynain Contour” function to support plotting of thickness information for
solid and T-shell elements.
·
Added
an option in the Offset Element function to allow the offset elements to
connect with the original mesh.
·
Improved
the “Penetration Check” function so that it will take the part thickness
property into account.
·
Improved
the “Check Coincide Nodes” function to check for duplicated nodes in the same
element.
·
Improved
the “Overlap Element” function to check for duplicated elements.
·
Added
an option in the Edit Default Config (Preprocess-General) window allowing the
user to delete free nodes while deleting parts, elements or merging nodes.
·
Added
an option to the “Project Line” function which allows the user to project line geometry
onto mesh.
·
Increased
the character length limit for material names from 8 to 65 characters.
·
Increased
the maximum number of points for a line from 500 to 5000.
·
The
size of the arrow shown in the display screen when measuring the distance
between points will depend on the view/zoom level not the distance.
·
The
show element normal function has been improved to will work with shaded model
display.
·
Definition
of Single Point Constraints in reference to a Local Coordinate System is
allowed.
·
Added
new “SuperAlloy” materials to the US material library.
·
Added
more materials to the Japanese material library.
Support LS-DYNA 971 R5
The input file created by eta/DYNAFORM 5.8 supports LS-DYNA 971R5 format.
Documentation
A Training Manual is available to assist first time
users with the general operating procedures of the program. The manual includes
a relatively simple demonstration of a draw die simulation of an S-channel and
introduces the processes of setup and draw die simulation in detail.
The
step-by-step procedure guides users through the complete process and flow of
tasks. A new user can usually complete the training program and be ready to
begin a production project in less than two hours.
An Applications Manual discusses the basics of the sheet metal forming process and transmits
some fundamental knowledge of tooling design and related topics to the
user. The following are typical examples
of simulations that are included to demonstrate eta/DYNAFORM’s capabilities,
features, and functions:
Case 1. NUMISHEET’2002 Fender Draw Simulation
Case 2. Double Action of Solid Element Simulation
Case 3. Springback and Springback Compensation Simulation
Case 4. Tube Bending and Hydroforming Simulation
Case 5. Multi-Step
Rotary
Bending
These
workshop examples enable users to fully understand general pre- and
post-processing operations in addition to the applications of binder wrap
simulation, draw bead force calculation, draw die simulation, Forming Limit
Diagram (FLD), thickness, thinning, wrinkling, and springback simulation.
The
eta/DYNAFORM User
Manual describes
functions of the software interface.
For further details about LS-DYNA, please
refer to the LS-DYNA Keyword User’s Manual published by the Livermore Software Technology
Corporation (LSTC) of