This function is mainly utilized for meshing flat and tubular blanks. This function allows the user to create the blank boundary line directly. The dialog box is shown in Figure 10.5.1.

Figure 10.5.1  Blank Generator Options

CREATE LINE

This function enables the user to create the blank boundary line directly. After clicking this option, the program will pop up the Create Line dialog box. Refer to Section 5.1.1 for detailed description. By clicking OK or the middle mouse button, the program will close the boundary line automatically.

BOUNDARY LINE

This function enables the user to create a flat blank mesh using boundary lines. After selecting the function, the user has to select the boundary lines using the functions provided in the Select Line dialog box. Upon completion of line selection, the Mesh Size dialog box illustrated in the Figure 10.5.2 is displayed.

Figure 10.5.2  Mesh Size dialog box

There are two methods for the user to define mesh size:

TOOL RADIUS –This input box enables the user to input the smallest concerned tool radius during the forming operation. Normally, it is the profile radius of the Die tool. The default Tool Radius is set as 6 (mm).

L (blank element size) = 16/3R (the smallest tool radius)

ELEMENT SIZE –This input box enables the user to input the average elements size for the blank mesh. The default Element Size (edge length) is set as 32.0 (mm).

CONVERT– This function enables the user to convert the Tool Radius to the Element Size or vice versa.

OK– This function enables the user to accept the defined parameters and continue the mesh operation. An eta/DYNAFORM Question dialog box illustrated in Figure 10.5.3 is displayed after the user selects OK.

Figure 10.5.3  eta/DYNAFORM Question dialog box

YES – Accept blank mesh.

NO – Cancel the operation.

REMESH – The Mesh Size dialog box is displayed. The user can modify the radius/element size.

Note: 1. The selected boundary lines should be lying on the same plane. Otherwise, blank mesh is generated on the least square plane of the selected line.
2. The orientation of layout of the selected line in the XY-Plane is important for the mesh. The user is recommended to rotate the lines along the Z-Axis prior to generating the blank mesh. Please note that different blank mesh is generated according to the different line orientation.

SURFACE

This function enables the user to create a flat blank mesh by selecting an existing surface. The meshing operation is quite similar to blank mesh generation using the boundary lines.

TUBE

This function enables the user to create the tubular mesh for tubular hydroforming and tube bending simulation. After the Tube function is selected, the Tube Parameter dialog box illustrated in Figure 10.5.4 is displayed.

Figure 10.5.4  Tube Parameter dialog box

SIZE –Enables the user to input average element size of tube mesh. The default element size is set as 2.0(mm).

NUMBER –Enables the user to input number of elements along the perimeter of tube.

TUBE DIAMETER – Enables the user to input diameter of tube. The default is 6.0(mm).

TUBE LENGTH – Enables the user to input overall length of tube. The default is 50.0(mm).

DEFINE DIRECTION – Enables the user to define the direction of tube mesh.

APPLY – Generate tube mesh with the set parameters.

UNDO – Cancel the generated mesh.

CLOSE – Exit the dialog box.