The functions enable users to:

l   Setup tooling models that are either built up by using other DFE functions or directly imported from outside eta/DYNAFORM;

l   Setup tooling as following process types;

­    Crash form

­    Single-action draw

­    Double-action draw

l   Setup draw beads;

l   Setup blank material, symmetry conditions and other constraints;

l   Setup binder with either force-controlled or displacement-controlled motion;

l   Setup lancing operations;

l   Setup adaptive mesh on blank;

l   Option for blank gravity loading;

l   Option for spring back simulation after forming simulation;

l   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.

  

Figure 7.7.4  Define Tool

Figure 7.7.5  Add Part

Figure 7.7.6  Add Elements

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.

          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

          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):

           

Figure 7.7.15  Define Symmetry

Figure 7.7.16  Symmetry Type

l   XZ Symmetry: defines symmetry plane which parallels to XZ-Plane;

l   YZ Symmetry: defines symmetry plane which parallels to YZ-Plane;

l   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

          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.

          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.

          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 0.00 mm indicates that the value of tool offset is also applied as the distance between the closed binder area as well as the punch and die in home position. Both fields accept positive and negative inputs for adding or reducing clearances. Be particularly careful when applying negative inputs, which may introduce tool over-travel and lead to wrong simulation results.

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.

          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.

          UNDO

 When clicked, it will discard the tool-positioning result.

          PREVIEW

 The function animates the tooling motion, and follows the procedure detailed in section 10.14, Animate.

          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.

          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.

          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