DYNAFORM 5.7.

3 Training Tutorial

Descriptions for Tipping, Inner Fill, Outer Smooth, Flat Binder Generation & Modification, Local Morphing of Parts and Die Face, etc. by using Door Inner, plus incremental analysis with Inc Solver.

I. Create and Save database

1. Click to create a new database.

2. Click File menu and select Save as button.

3. Enter the file name: Doorinner_(user name)_(date).df 4. Click Save to save the database.

II. Import Part Geometry

1. Click DFE (See Figure 1).

2. Select Preparation.
3. Click IMPORT button in Define page. 4. Select file location: /Tutorial4_DoorInner 5. Select file: door_inr.igs

6. Click Ok button to import part geometry.

Figure 1

II. Import Part Geometry

Figure 3 Figure 2

III. Rename Part

1. 2. 3. 4. Select the imported part DIEPART in the Die Tool list. Click Rename (See Figure 4). Enter the new name DOORINN in the input box for New Name. Click Apply after modification.

Figure 4

Figure 5

IV. Auto-mesh Surfaces

1. Select DFEPreparation 2. Click Surface Mesh (See Figure 6) and click Select Surface in the displayed Surface Mesh window (See Figure 7). 3. Click Displayed Surf. button to select all the surfaces displayed on screen (See Figure 8). 4. Toggle on Exclude (See Figure 8). 5. Select flange surfaces on screen (These surfaces cannot be formed during drawing, so they should be removed during drawing) (See Figure 9). 6. Click OK to confirm the selected surfaces. 7. Return to Surface Mesh window. 8. Key in the Max. Size: 20.00 (mm) 9. Click Apply to mesh. 10. Click Yes to accept mesh. 11. Click Exit to exit the Surface Mesh dialog box. 12. See Figure 10. 13. Click to save the database.
7

Figure 8

Figure 6

Figure 7

IV. Auto-mesh Surfaces

Remove flange surface

Figure 9

Figure 10

V. Check and Repair Mesh

1. select DFE Preparation Model Check/Repair (See Figure 11). 2. Click Boundary Display icon (line one, column two) (See Figure 12). Note: repair the failed elements 3. Click (Clear highlight) to clear the highlighted boundary lines. 4. Click Plate Normal icon (line two, column two). 5. Check the message prompt window to make sure that all element normal is consistent. 6. In order to make all the mesh normal directions pointing to the upper side of part, click the first button Auto plate normal in the first line (See Figure 13). 7. Select Cursor Pick Part in the displayed control keys window, which means that only the normal directions for the current part mesh will be changed. 8. Select a mesh on the door inner panel. 9. If the normal directions are accepted (pointing to the part exterior), then click Yes, otherwise click No. 10. Click Exit to exit Auto plate normal menu. 11. Click OK to exit Model Check/Repair menu.
10

V. Check and Repair Mesh

Figure 12 Figure 11

11

V. Check and Repair Mesh

Figure 14

Figure 15

Figure 13 Figure 16

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VI. Tipping
1. Select TIPPING from DFE / preparation.

2. Toggle on Undercut (See Figure 17.a).

3. The current part is not appropriate to be stamping direction because many regions on part are red as shown in Figure 17.b. 4. First, define the values for Tipping Center (process base point, i.e. the rotation point for part): X=3800, Y=-900, Z=1100. The system will automatically generate three straight lines to

represent the three positive directions of the original coordinate system.

5. In the input box next to Step under Manual Tipping, type in the rotation angle for the first time: 100 (degree). 6. Select X Axis as the rotation axis and click the third button is shown in Figure 18.b. 8. In the input box next to step, type in the rotation angle for the second time: 90 (degrees). 9. Select Z Axis as the rotation axis and click the third button 10. At present, the top view for part is shown in Figure 19.b. (counter-clockwise). (counter-clockwise). 7. The system will automatically record this tipping information in the Process Record list. The part

11. The system will automatically record the second tipping information in the Process Record list.
12. Click Exit to exit Tipping dialog box.
13

VI. Tipping

(b) (a) Figure 17

14

VI. Tipping

(b)

(a)

Figure 18

15

VI. Tipping

(b)

(a)

Figure 19

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VII. Inner Fill

1. Click DFE PREPARATIONBoundary FillInner Fill 2. Select the first icon Auto Fill (See Figure 20.a). 3. Enter Hole in the input box of To Part, which means to put the generated filled holes to Hole part. 4. Click apply to confirm. Click on the middle mouse button to confirm the selected holes to be filled in the current view (Note: click on the left mouse button to remove the filled holes and the right mouse button to cancel all the holes, as illustrated in Figure 20.b and 20.c). The inner holes will be filled automatically. 5. Click Close to exit INNER FILL dialog box. 6. Click to show the top view. 7. See Figure 21.

17

VII. Inner Fill

(c)

(b)

Figure 20
(a)

18

VII. Inner Fill

a before inner fill

bafter inner fill

Figure 21

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VIII. Outer Smooth

1. Click DFE PREPARATIONBoundary FillOut Smooth
2. Click Select part and select hoodinn (See Figure 22.a and 22.b). 3. Select the first button Roller and the system will enter DOO_SMH in the input box of To Part. 4. Key in Roll Radius: 300.00 (mm) 5. Click Create Boundary. 6. Click Fill Boundary to fill.

7. Click Exit to exit Outer Smooth dialog box.

8. Repeat the above step VII to check and repair mesh. 9. See Figure 23.

20

VIII. Outer Smooth

(b)

(a)
Figure 22

(c)

21

VIII. Outer Smooth

Delete some elements by manual. 1

Result after boundary smooth

Figure 23

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IX. Create and Modify Binder

1. 2. 3. 4. 5. Click Binder in DFE menu. Select Binder Type: Flat Binder (See Figure 24.a). Key in Binder Margin: 400.00 (mm) Key in shift: 20.00(mm) Click Apply to create binder. The front view is shown as Figure 24.b. The letter color of Create turns from red to black. 6. Do not click Exit. Then we will change the binder from flat to single surface. 7. Click Modify to modify the binder. Switch to top view. 8. Click Add to add a section. Toggle on By input and key in: dx=0dy=0 (See Figure 25.a). 9. Click vector to define section direction. Click u in the displayed window and u=1, which means the section is along X axis (See Figure 25.b). Click OK to confirm. 10. Return to Modify. Click create to add a section cntrl ln:0, which passes through the origin and is parallel to X axis, to control lines list box (See Figure 26). (to be continued)

23

IX. Create and Modify Binder

(a) (b)

Figure 24

24

IX. Create and Modify Binder

(a) Figure 25

(b)

25

IX. Create and Modify Binder

(a)
(b) Figure 26

26

IX. Create and Modify Binder

continued 11. Click Add to add another section along Y axis. Toggle on By Input and key in dx=500,dy=0 (See Figure 27.a). 12. Click vector to define section direction. Click v in the displayed window and v=1, which means the section is along Y axis (See Figure 27.b). Click OK to confirm.

13. Return to Modify page and click create button to add a section cntrl ln:1, which passes through (500,0)(relative to process base point) and is parallel to Y axis, to control lines list box (See Figure 28).
14. Select the first section cntrl ln:0 in control lines list box and click Edit (See Figure 28). 15. The program pops up the 2d curve window for section modification. Click to switch to front view of part, which is convenient for viewing during modification of control lines.

27

IX. Create and Modify Binder

(a) (b)

Figure 27

28

IX. Create and Modify Binder

(a)

(b) Figure 28

29

IX. Create and Modify Binder

(a)

Figure 29 (b)

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IX. Create and Modify Binder

continued 16. Select the left line segment in 2d curve window and click Straight to define it as straight line; then, select the right line segment and click Straight to define it as straight line (See Figure 30). 17. Hold Shift key and use the left mouse button to add a control point near the intersection of the left line segment and Y0 line (See Figure 31). At present, there are four control points on the section along X axis: A,D,C,B (from left to right). 18. Adjust the coordinates for four control points in sequence. The z values for points A, B, C , D are 80, 160, 10 ,-100 . Key in the fillet radius r=1300 after point D is selected (See Figure 31.b). 19. At present, the front view is shown as Figure 32. 20. Click Apply to accept the current profile operation and click Close to exit 2d curve window. 21. Select the second section cntrl ln:1. This section increases upward to the location with z=0 automatically but still remains a horizontal line, which is in accordance with the binder requirements for door inner panel and does not need to be modified (if it is not a horizontal line, the z values for the left and right endpoints need to be changed to -40). 22. Click Apply to change the binder from flat to single surface. 23. Return to Bindercreate page and click Mesh to mesh binder. The Max. and Min. Size are 50 5. Then the operation for Create and Modify Binder is completed (See Figure 33). 24. Click Exit to exit binder window.

31

IX. Create and Modify Binder

Select the left line segment

Select the right line segment

(a)

Figure 30

(b)

32

IX. Create and Modify Binder

Add a control point here

(a)

Figure 31

(b)

33

IX. Create and Modify Binder

Figure 32

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IX. Create and Modify Binder

Figure 33

35

X. Create Master Profile

1. Click DFE. 2. Select Addendum. 3. Select New in the displayed dialog window to create a new master profile (See Figure 34.a). 4. Select Profile Type: Profile Type 1 (See Figure 34.b). 5. Click Ok to exit Master Profiles dialog window (See Figure 34.c). 6. Click New to create another new master profile. 7. Select Profile Type: Profile Type 2. Key in 10.0 in the input box next to Part under Plus (See Figure 35.b). 8. Click Ok to exit Master Profiles dialog window.

36

X. Create Master Profile

(a)

(b)

Figure 34

(c)

37

X. Create Master Profile

(a)

(b)

Figure 35

(c)

38

XI. Create Addendum

1. 2. 3. 4. Select Master 1(type1) as the master profile to create addendum. Click Assign (Addendum) (See Figure 36.a). Select Addendum Type: Outer (See Figure 36.b). Toggle on By Segment and click Select Region to generate addendum by segment. 5. Select the starting point A for addendum at the vertical flange above the glass window of door inner panel, and select the endpoint B at the end of vertical flange (See Figure 37). 6. Click Yes to confirm the selected region. Click Apply to generate addendum. Click Close to exit. 7. Then select Master 2 (type2) as the master profile to create addendum. 8. Repeat steps 2) to 4). 9. Select the remaining boundary lines as the region of addendum. 10. Click Apply to generate addendum (See Figure 38).

39

XI. Create Addendum

End point of vertical flange

(b)

(c) (a) Starting point of vertical flange Figure 36

40

XI. Create Addendum

(c)

Starting point A of addendum

(a)

Endpoint B of addendum
Figure 37 (b)

41

XI. Create Addendum

Figure 38

42

XII. Smooth Addendum

1. Click Modify under Addendum (See Figure 39.a). 2. Select Smooth and POP line (See Figure 39.b). 3. Click Apply and click the left mouse button near the addendum to be modified at the left corner of door inner panel (the first region in Figure 41). 4. Select Through Fixed Points (See Figure 39.c). 5. Use the rotation and zooming button to check the region as shown in Figure 40. 6. Click Select Fixed Points and select four points on addendum (See Figure 40). 7. Click Preview to preview the modified pop line. 8. Click Apply. 9. Click OK. 10. Repeat steps 2 to 9 to smooth 2, 3, 4 (to be continued).

43

XII. Smooth Addendum

(c)

(a)

(b) Figure 39

44

XII. Smooth Addendum

POP line after smooth
POP line before smooth
P3 P4

P2 P1

45
Figure 40

XII. Smooth Addendum

11. Click Close to close Smooth Addendum dialog box. 12. Delete the profile between two points marked in region 5 (See Figure 41). 13. Click OK to confirm deletion (See Figure 41).

1 2 1 2
46

XII. Smooth Addendum

5 1

4 3
Figure 41

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XIII. Create Addendum Surface

1. Click Generate (See Figure 42.a) 2. Select POP Line, Profile Line, Addendum Surface and click Apply to generate addendum surface automatically (See Figure 42.b). 3. Click Close to exit and save the database.
(a) (b)

Before generating surface Figure 42

After generating surface

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XIV. Binder Trim

1. Click DFE Modification (See Figure 43.a). 2. Select BINDER TRIM (See Figure 43.b). 3. Select Binder Type: Outer 4. Toggle off Surface. 5. Click Select (See Figure 43.c). 6. Select Trim Line (See Figure 43.d). 7. Click Ok to confirm. 8. Click Apply. 9. Click Yes to accept the displayed line. 10. Click Close to exit Binder Trim dialog window. 11. Click to show the top view. 12. Toggle off all the parts except C_BINDER (See Figure 43.e). 13. Click Close to exit MODIFICATION dialog box. 14. Toggle on Surface. 15. Save the database.
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XIV. Binder Trim

(a)

Binder trim line

(b)

(c)

Figure 43 (d) (e)

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XV. Unfold Flange and Create Trim Line

1. 2. 3. 4. Click DFE. Select Preparation. Select Unfold Flange (See Figure 44). Use rotation and zooming tools to check the region as shown in Figure 45.d. 5. Select the flange surfaces to be unfolded (See Figure 45.d. 6. Click OK to confirm. 7. Accept the base surface and unfolded line obtained from automatic calculation (See Figure 45.b). 8. Enter the bent angle and click OK to confirm. 9. The system will automatically calculate the flange line. Click Done to exit. 10. The surface will be unfolded to the addendum automatically to generate unfolded line. 11. Repeat 3 to 10 to unfold other flange surfaces. 12. Click Exit to exit DFE Preparation dialog box. 13. Save the database.

Figure 44

51

XV. Unfold Flange and Create Trim Line

(c)

(e)

(b)

(a)

Figure 45

(d)

52

Die Face Design completed, setting up for the analysis

Build a Blank
1. Click Parts. 2. Select Create 3. Type Blank in the Name.

Mesh the Blank

1. Click Blank Generator 2. Select Create Line 3. Select pick the corner location of the blank

Mesh the Blank

1. Click Boundary Line 2. Select the blank outline 3. Enter 20 for blank element size

Mesh the Blank

Click Yes to accept the mesh

Blank Mesh

Setting up Formability
Select DFE/Formability

Setting up Formability
1. Select Single action 2. Select Upper Tool Available 3. Select Blank

Define Blank
1. Click Select Part

2. Select Add 3. Select Blank Part

Select Blank Material

Select Blank Material as DQ

Setting up Formability
1. Click Apply 2. Select Preview 3. Select Submit job

Submit the Job

Thickness Contour Plot

Forming Limit Diagram

Input file information

Input file name for this tutorial is: door_inr.iges
If you have any question regarding this DFE and INC Solver Tutorial, please contact support@eta.com