DYNAFORM

Die System Simulation Package

Sherpa & INCSolver based

Sheet Metal Forming Optimization
with DYNAFORM/OP Module
DYNAFORM Team
Sepetember, 2013
1

Brief History of DYNAFORM

1983 Coded METALFORM for Ford Science Laboratory
1993 Started the development of DYNAFORM

1995 Signed LS-DYNA Bundling Agreement with LSTC

1999 Released Windows/PC to Tool & Die Industry
2000 Started developing Die Face Engineering (DFE) module
2001 Unified Windows/Unix/Linux platforms
2002 Released first version of DFE module
2003 Released BSE (Blank Size Engineering) module and MSTEP
2004 Delivered Die Structure Analysis (DSA)

2005 Delivered Springback Compensation (SCP) Module

2006 Released 5th Generation of DYNAFORM with Auto Setup
2008 Released DYNAFORM 5.5 and 5.6
2009 Released DYNAFORM 5.7.X

2010/2011 Released DYNAFORM 5.8.X

2013 Releasing DYNAFORM 5.9.1 Optimization Platform Module (OP Module)
2

DYNAFORM Capabilities Summary DF 5.9.1

BSE (Blank Size Engineering)
Blank Outline, Blanking, Nesting
Material Cost Estimation

DFE (Die Face Engineering)

Binder and Addendum Generation, Drawbead Layout
NURBS CAD Surface Based Technology
INCSolver for Formability

Formability (LS-DYNA & LS-OPT based Forming Simulation Solution)

Accurate Solution, strength in Springback and Springback Compensation

Massive Parallel Processing (CPUs) for analysis lead-time reduction
LS-OPT Optimization (DF 5.9 Release)
Blank Development (Iterative Approach)

OP (Optimization Platform)
Sherpa Optimization Engine
INCSolver Incremental Solver for Sheet Metal Forming Simulation

DSA (LS-DYNA based Die System Analysis)

DSI,SMTH & SSR

Forming Based Optimization Functions

Drawbeads are designed to restrict the blank from wrinkling & splitting during a forming
process
Adjusting the configuration of Drawbeads on a complicated drawbeads setup can be very
challenging & time consuming. Achieving a formable panel/part, can take weeks!

By efficiently utilizing the Optimization technology made possible with modern computing
power, drawbead force optimization is now practical, and can achieve an optimum
configuration in a reasonable time frame, days.
Die Face

19 Line Beads

Blank

Binder
Punch

Typical Die Face Layout

Typical Draw Beads Parametrically Defined

Round Bead

Square Bead

Male Bead & Female Bead

More discussion on Slide 17
5

Optimization Based on (6) FLD Zones

Forming Limit Diagram (FLD)
Zone3 ( Split or Fail)
Zone 4 (Wrinkle Tendency)
Zone2 (Marginal)
Zone 5 (Wrinkle)
Zone 1 ( Safe)
Zone 6 (Severe Wrinkle)

Define the Constrain/Objective function as the ratio

of elements in a particular Zone # / total elements
6

Implementation Strategy
Adopt Sherpa which is the Optimization Engine
Build a Black Box solution with a set of simple Dialog Boxes for
DYNAFORM users, mainly tool & die designers, to define the parameters
and optimization objectives, etc.

Adopt ETAs INCSolver , a single purpose, accurate forming solver,

taking advantage of the latest multiple-core CPUs computing power
Optimize the formability of deep draw & stretch forming applications
Primary : Drawbead Force Rate in terms of percentage to the 100% Lock Bead design
Secondary : Binder Force, Lubrication, Material and Gage

INCSolver Introduction (I)

INCSolver is a Nonlinear Transient Dynamic Finite Element Program
Using Explicit Scheme to solve Equations of Motion
Commonly referenced as Incremental Code or Explicit Code
Developed for the single purpose of simulating sheet metal forming processes
Belytschko-Tsay Shell Element is used for the simulation of sheet metal in the forming
processes
a.k.a BT Shell Element
Penalty Method is used for the simulation of Contact between die face and sheet metal in
the forming processes
Nonlinear Material Property supports Hills Yielding Criteria
Both Fusion & Fission Adaptivity of the blank during the forming process is offered to
adjust the mesh density in every time step
8

INCSolver Introduction (II)

INC Solver using the SMP (Shared Memory Processing) computing scheme to take
advantage of multiple-CPUs, Multiple-Cores and Multiple-Threads of the latest computing
platforms, in Windows environment
Intel Core i7 CPU systems with (4) multiple-cores are recommended for the best
price-performance
Execution turn around timing is practical in supporting a die face design objective
Example: An investment of less than $1500 in computer hardware, such as a 4Core/8 Total Thread system, will be capable of simulating the largest most
demanding panel applications, such as Body Side Frame formability in less than 60
Minutes. (see animation on the first slide)
INC Solver has the ability to work well with non-connected tool mesh generated from
non-conforming CAD surfaces
Strict connectivity is not necessary, and is compensated for by the built-in flexibility
of the INCSolver
Overlaps, Gaps and mesh defects for rigid body can all be handled by the INCSolver
Formability results are mostly matching with the hardware and NUMISHEET benchmark
cases results
9

INCSolver Features & Functions Summary

Gravity Load & Binder Wrap Simulations

Crush Forming Simulation
Single Action Simulation
Double Action Simulation

Validation Cases are available for review

and examination, presented separately.

10

Optimization Flow Chart

FORMABILITY

Optimization GUI
End

Sherpa

Update Database
with (5) Optimized
Cases / Formability
Performance

Run INCSolver

eta/Post Extraction Scripts

Update Response

11

GUI of Optimization Overview

Definition Forming
Stages Design
Variables

Define Objectives
and Constrains

Optimization
Solver Status
12

Case 1, Sink, Deep Draw Optimization Setup

Bead 1, bead 2 , bead 3 and bead 4 should be symmetrical, and the bead 2, bead 3 and bead 4
are defined as dependant of bead 1. The baseline Values are changed incrementally in a range
from 5% to 90%. The base line of each variable is 25%. The incremental drawbead rate is 5%.
4 Line Beads

Objective and constraints are all Crack and Safe. The allowable thinning 20%.
The number of Evaluations is 100. Due to the dependency, it reduced to 18.
13

Case 1: Optimization Result

SHERPA returns with (5)
best/optimized Cycles 1 Line
Bead Rates due to symmetry.

Higher Positive SAFE values indicate

better optimized results. Negative
SAFE values indicate a bad cycle.
Bead ID

Base Line

Optimized

25

70

Optimization Performance is
measured according to the relationship
with objectives and constraints. A
positive and larger value means better
design, a negative value indicates ill
condition or infeasible
14

Case 1: Optimization Performance Before / After

Comparison

Full model 25% Drawbead Force Lock Rate

Before Optimization, FLD Plot

Full Model 70% Drawbead Force Lock Rate

After Optimization, FLD Plot
15

Case 1, Sink, Computing Resources

CASE 1

Sink

Objective and
Constraint
Crack, Safe

Iteration

CPU

Calculate Time
( Hours)

18

Intel(R) Core(TM) i7-2600 CPU

@3.40GHz 3.70 GHz
1 CPU/4 cores/8 threads

16

Implement Optimization Results

Bead ID

Base Line

Optimized

25

70

17

Case 2: Deep Draw setup, Full Blank, Full Tools,

Adaptive Level 4

Draw Setup Parameters

Material
Thickness:
Friction:
Blank size:
Adapt mesh levels:

DC04
1.2mm
0.125 0.125 0.125 0.125
16
4

18

Case 2: Optimization Setup

7 Line Beads were setup for optimization, and the other beads are defined as dependant of
them. The baseline values are changed incrementally in a range from 5% to 90%. The base line
of each variable is 25%. The incremental rate is 5%.

Objective and constraints are all Crack and Safe. The allowable thinning 20%.
The number of iterations is 130. The C-Crack is set as 0.01.

19

Case 2: Optimization Result

SHERPA returns with (5) best/optimized
Cycles 7 Line Bead Rates. The first
one(Cycle 119) is as shown in the table
#3
below.
#6
(30%)
(20%)
#8
#2
#10

(55%)

(5%)

#13

(15%)

(35%)

#11
(55%)

#14

#1

(55%)

(35%)

#12
(15%)

#9
(55%)

#7

#4

#5

(20%)

(5%)
(30%)
Optimized

Bead ID

Base Line

25

35

25

25

30

25

20

25

55

10

25

15

11

25

55

20

Case 2: Optimization Performance

Before / After Comparison

Full model 25% Drawbead Force Lock

Rate Before Optimization, FLD Plot

Full Model , Drawbead Force Lock Rate

After Optimization, FLD Plot

21

Case 2: Oil Pan, Computing Resources

CASE 1

Oil

Objective and
Constraint
Crack, Safe

Iteration

CPU

Calculate Time
( Hours)

130

Intel(R) Core(TM) i5-3570 CPU

@3.40GHz 3.40 GHz
1 CPU/4 cores/4 threads

42

22

Case 3: Cross Member (NUMISHEET05), Draw Setup

Optimize (20) Line Beads

Draw Setup Parameters

Material
Thickness:
Friction:
Blank size:
Adapt mesh levels:

DP600
1.6mm
0.125 0.125 0.125 0.125
16
4

23

Case 3: Optimization Setup

10 Line Beads were setup for optimization, and the other beads are defined as dependant of
them. The baseline values are changed incrementally in a range from 5% to 90%. The base line
of each variable is 75%. The incremental rate is 5%.

Objective and constraints are all Crack and Safe. The allowable thinning 20%.
The number of iterations is 150. C-Crack is set as 0.01.

24

Case 3: Optimization Result

SHERPA returns with the (5)
best/optimized parameters 10
Line Bead Rates. The Cycle 138
is shown in below table.

Bead ID

Base Line

Optimized

75

65

75

70

75

70

75

75

75

75

70

75

90

75

70

75

90

10

75

85

25

Case 3: Optimization Performance

Before / After Comparison

Full blank 75% Drawbead Force Lock Rate

Before Optimization, FLD Plot

Full blank, Drawbead Force Lock Rate

After Optimization, FLD Plot
26

Case 3: Cross member, Computing Resources

CASE 1
Cross
member

Objective and
Constraint
Crack, Safe

Iteration

CPU

Calculate Time
( Hours)

150

Intel(R) Core(TM) i5-3570 CPU

@3.40GHz 3.40 GHz
1 CPU/4 cores/4 threads

40

27

Case 4 DeckLid (NUMISHHET05), Stretch Forming

Optimize 22 Line Beads

Die Face

Draw Setup Parameters

Material
Thickness:
Binder Force
Friction:
Adapt mesh level:
Initial element size:
Lower Binder Travel

BH180
0.8mm
133400.00N
0.125 0.125 0.125 0.125
4
16mm
1mm
65mm

Blank
Binder

Punch

28

Case 4: DeckLid, Optimization Setup

11 Line Beads were setup for optimization, and the other beads are defined as dependant of them,
Baseline values are changed incrementally in a range from 5% to 90%. The base line of each
variable is set at 60%. The incremental rate is 5%.

Objective and constraints are all Crack and Safe. The allowable thinning is 20%.
The number of iterations is 162. C-Crack is set as 0.01.
29

Case4: DeckLid, Optimization Results

SHERPA returns with the (5)
best/optimized parameters 11
Line Beads Rates, Cycle 149 is
presented

Bead ID

Base Line Rate

Optimized

60

50

60

50

60

70

60

85

60

50

60

30

10

60

90

11

60

50

12

60

45

13

60

35

14

60

60

30

Case 4: DeckLid, FLD Plot Before and After

Optimization

Crack / Split

Before Design Optimization

Crack / Split

After Design Optimization

After the Design Optimization, based on FLD presentation, the Crack/Split area is
significantly reduced.
31

Case 4: DeckLid, Computing Resource

CASE

DeckLid

Objective and
constraint
Crack, Safe

Iteration

162

CPU
Intel(R) Core(TM) i7-2600 CPU
@3.40GHz 3.70 GHz
1 CPU/4 cores/8 threads

Calculate Time
( Hours)
74

32

Case 5: Fender (NUMISHEET02), Stretch Forming

Die Face
16 Line Beads

Draw Setup Parameters

Material
Thickness:
Binder Force:
Lower Binder Travel:
Friction:
Adapt mesh level:
Initial element size:

HSS_FENE
0.7mm
1200000N
130mm
0.125 0.125 0.125 0.125
4
16mm
1mm

Blank

Punch

Binder

33

Case 5: Fender, Optimization Setup

5 Line Beads were setup for optimization, and the other beads are defined as dependant
of them, The baseline values are changed incrementally in a range from 5% to 90%. The base line of each
variable is set at 60%. The incremental rate is 5%.

Objective and constraints are all Crack and Safe. The allowable thinning is
20%. The number of iterations is 130. C-Crack is set as 0.01.
34

Case 5: Fender, Draw bead definition

5 Line Beads were setup for optimization, and the other beads are defined as
dependant of them, the relationship is as shown :

Define Drawbead (2) Types :

Type 1, Continuous Setting
allows user to set an evaluation
range individually for each bead
Type 2, Dependent Setting
allows for bead rates to be set in
accordance with an associated
bead, as with symmetric parts

35

Case 5: Fender, Optimization Results

SHERPA returns the (5) best/optimized
parameters 5 Line Beads Rates. The
Cycle 95 is as shown in below table.

Bead ID

Base Line Rate

Optimized

60

15

60

20

60

75

60

30

15

60

25

36

Case 5: Fender, FLD Plot, Before and After Optimization

Before Design Optimization

After Design Optimization

After the Design Optimization, based on FLD presentation, the Crack / Split area is
significantly reduced.
37

Case 5: Fender, Computing Resource

CASE

Fender

Objective and
constraint
Crack, Safe

Iteration

CPU

Calculate Time
( Hours)

130

Intel(R) Core(TM) i5-3570 CPU

@3.40GHz 3.40 GHz
1 CPU/4 cores/4 threads

37.5

38

Conclusions and Discussions

Sherpa and INCSolver based Formability Optimization is practical for
the evaluation of drawbead layouts, and determining the rates in terms
of the drawbead Lock Rates (100%)
Black Box setup enables average tooling users to quickly adopt the
optimization approach for forming applications
SMP & Multiple CPUs / Cores computing is recommended for
demanding optimization calculations

Accept the multiple solution scheme of forming a part

Determines the best solution per tooling design requirements

Follow the Best Practices to use INCSolver and OP Module

See appendix for the said Best Practices
Validation cases are provided for review
Training & Tutorial cases are available
39

Thank you for using DYNAFORM !

40

Best Practices for using

INCSolver

41

Best Practices Initial Blank Mesh (I)

The initial blank mesh should be as uniform as possible
Using DYNAFORMs Part Mesher
If the size difference between elements exceeds the ratio of 10:1, the
job submission will be rejected.
The recommended initial number of elements on a blank is between

1000 and 8000 elements

For very small parts, 300 elements is acceptable
The adaptive mesh can be used as an alternative way of controlling the
initial number of elements on the blank.
When specifying the refinement level of adaptive mesh, the numerical

number entered equals the maximum number of times that each

element can be split during simulation
i.e., adaptive level = 3 means that an element can be split 3 times from
its initial blank size

42

Best Practices Initial Blank Mesh (II)

The initial mesh size and adaptivity level should be determined based

on the minimum draw radii on the die face, for example:

If the minimum draw radii is 6 mm, the common practice is to have (3)
rows of elements to adequately define this 6 mm draw radii. In this case,
the minimum element size after (3) level of Adaptivity would be 2 mm. So,
the Initial Blank Size should be defined as 16 mm.
If the user prefers to use (4) level of Adaptivity, the Initial Blank Size
should be set to 32 mm.
Avoid generating a minimum element size smaller than the thickness of the
blank. Defining a minimum element size smaller than the blank thickness will
result in an ill condition of the formability solution, and an ill condition
optimization solution.

Best Practice is to use adaptivity (3) or (4)

Avoid using adaptivity level (2), as it might not adequately define the
small radii
Avoid using adaptivity level (5), as it might create element sizes that are
smaller than the thickness of the blank
43

Best Practices Die Face Modeling

Die face surfaces are meshed using DYNAFORMs Tool Mesher

Non-conforming mesh is handled by the INCSolver, and no mesh

check/repair tasks are required
Die faces are defined as rigid body
No boundary conditions or constraint equations should be imposed
on the die face mesh, or any rigid body
It is strongly recommended that full die face & full blank be used in
simulation instead of its symmetric or asymmetric half
To create a full die face from a half model, use functions in
DFE/Preparation/Symmetry/Double Attach
44

Best Practices(INCSolver) Setup (I)

When starting with product design geometry:
1. In DFE, import product surfaces and create mesh, tip if necessary;

2. If it is a symmetric or asymmetric half, create the full model using the

functions in DFE/Preparation/Symmetric/Double Attach;
3. Create binder and addendum;
4. Exit DFE and create a blank using the functions in Tools/Blank Generator;
5. Select DFE/DFE Simulation, and the model created in DFE is already
recognized as the original die face shown in green, and recommended Draw
type is highlighted;

45

Best Practice Setup (II)

6. Define the available side of the die face using the pull-down menu;
7. Define the blank and material;

8. Define draw beads, if any, and attach to the die (not the binder);
9. For a force-controlled binder, check in the Binder Force field and enter
the value (N).
10. For a distance-controlled binder, default settings for both tool offset and
binder gap are 110% of the blank thickness. To customize, click the
Advanced button.
11. Click Apply to position the tools. Animation is available by clicking
Preview;
12. Click Submit Job, and enable Gravity loading if needed. Enter
refinement levels for Adaptive mesh, and then Submit.

46

Best Practices (INCSolver) Setup (III)

When starting with importing die face geometry:
1. In DFE, import the CAD surfaces and create mesh, tip if necessary;
2. If it is a symmetric or asymmetric half, create the full model using the
functions in DFE/Preparation/Symmetric/Double Attach;
3. Exit DFE and create a blank using the functions in Tools/Blank Generator;
4. Select DFE/DFE Simulation, and define the Draw type and the available side
of tools using the two pull-down menus;

5. Click labels and assign geometries to the tools;

47

Best Practices (INCSolver) Setup (III)

6. Define the blank and material;
7. Define draw beads, if any, and attach to the die (not the binder);
8. For a force-controlled binder, check the Binder Force field,, and enter
the value (N).
9. For a distance-controlled binder, the default settings for tool offset and
binder gap are both 110% of the blank thickness. To customize, click
the Advanced button.
10. Click Apply to position the tools. Animation is available by clicking
Preview;
11. Click Submit Job and select Gravity loading is needed. Enter
refinement levels for Adaptive mesh, and then Submit.

48

Best Practices for using

OP Module

49

Best Practices Draw beads Layout

and Definition
Follow the tooling design guideline for laying out a die face that could
be implemented in a tooling shop
Usually, the drawbead rate is given in the increment of 10%, and the OP Modules
default increment is 5%
Usually, minimizing the number of different drawbeads is more desirable, and wiselygrouping the drawbeads will save calculation resources
It is undesirable to have a large deviation between neighboring drawbeads

Define the dependency for symmetrical drawbeads for symmetrical forming

applications.
The association formula can be used to define asymmetrical drawbeads with
attachment relationships.
The formula can be specified by users themselves. For example, if there are three
drawbeads A,B and C, then C=(A+B)/2. The user is allowed to define the attachment
relationships between C, and A and B according to this formula.

Defining the Base line with an educated guess is also a good practice.
For Deep Draw applications, the baseline should not be larger than 75%. A starting
point of 25% might be more suitable for deep draws. Overall, the optimization result
will be better with an appropriate baseline definition.
50

Best Practices Manage these Parameters

Number of Evaluation Cycles or referenced as Iterations is determined by the
given targets, constraints, incremental rate, and defined variables.

A formula is available in the Users Manual for reference

Usually, the estimated Number of Evaluation Cycles calculated by the formula is

sufficient. If needed, the user can add (or subtract) a percentage of additional
Evaluation Cycles (Iterations) to get a more refined resolution (or a less refined
resolution that isnt as resource demanding).
Defining the Optimization Range with an educated guess will also be a good
practice. For example, for area with historical wrinkle problems, it uses a range
that is higher in rates. And for areas with historical split/crack problems, it uses
a range that is rather lower in rates.
Define the Objectives which are of interest to the user. The Constraints are
related with Objectives. The optimized draw bead results are different
according to different Response definitions. The user should define the
Response by his/her request.

51

Best Practices Optimization Performance

OP Module will produce multiple solutions, which are judged by Optimized
Performance.
Optimized Performance is evaluated against the given Objective and
Constraint. The details on the formula for calculating performance are provided
in Sherpa Users Manual.

The large positive normalized number indicates a healthy optimization, larger is better.
The large negative normalized number indicates the ill condition or infeasible results, and
Sherpa will discard this particular cycle for evaluation.

It is possible to derive a most optimized single solution which will require very
fine resolution in the Optimization Range, many Evaluation Cycles and huge
calculation resources

This most optimized single solution might be difficult to implement, compared to the one that is
implemented in the tooling shop

52

Best Practices Result viewer

It is highly recommended to use the default setup parameters to calculate
multiple solutions.

OP Module produce (5) top performers for selection

User can check and review the Best results with the Postprocessor. Once
selected, the OP module will automatically input the optimized bead rates
into the Drawbead GUI of the INCSolver.
Allow the user to check the results through the optimization performance,
and show the graph with different Responses and Cycles.

Once Check by Performance is toggled on, the program will relist all results from small to
large per performance.
User can select any cycle performance to review in Graph.

For the Graph, Define different Responses as X axis and Y axis

respectively. All cycles can be animated.

53

Best Practices Deviation

There is a known source of deviation.

Introduced due to the forming contacts, adaptivity and explicit solution of theINCSolver in a SMP
environment (in the range of 5% deviation)

One possibility is that OP Module will derive different solutions due to the
deviations introduced by the INCsolver.
To avoid this occurrence, the user should set up the constraint targets to
account for this variation. For example, if the variation in a response is
expected to be 0.1, the user cannot specify a constraint target of 1.0e-7 and
expect the results from different executions of the same optimization to produce
the same results.

54

Best Practices(OP) Setup (I)

When starting with product design geometry and importing die face geometry :
1. Before entering OP, the user should complete the INCSolver setup. Please
refer to the Best Practices (INCSolver) or the users manual of INCSolver in
DFE for detailed information.
2. Set up INCSolver, and the baseline of bead rate should be set properly for
different models;

3. Select OP/Optimization, and select the draw bead as the optimization variable
4. Define Continue or Depend on for each drawbead, determined by the
relationship of beads
5. Define Responses for defined variables.
6. Define Objectives and Constraints for defined variables;
7. Use default thinning value and Evaluations number;
8. Click the Run button to submit the job;

55

Best Practice(OP) Setup (II)

9. Once the calculation is completed, the program will generate *.res and *.rpt
files under the directory location as the saved database file (*.df)
10. Once the calculation is completed, the status frame will be highlighted in red.
Click the Result button to check the optimized bead
11. Open Result Viewer GUI, and the program will show the 5 best results;
12. Select any best result and then click the View button, and the program will
open the Postprocessor to analyze the forming result
13. Select the desired best result from the 5 options and then click Apply button,
and the optimized rates will be set as bead rates in INCSolver;
14. Click on Check by performance, and the cycles-performance information will
be listed from small to large;
15. Select Crack as X axis and select Cycle as Y axis, and the graph will be
displayed.

56

The Input files for the above presented (5) cases are
available for training and reviewing results purpose.
Validation cases are also available per request.

57