Calculation of the Part boundary Calculation of the Part boundary Calculation of the Part boundary

Calculation of the Part boundary Calculation of the Part boundary Calculation of the Part boundary

Prepare Prepare Prepare Prepare Part boundary generation > Error tolerance: 0.1 > Concatenation

distance: 30.00

To confirm the above selection, click on the button Apply

Fig. 4.3 Fig. 4.3 Fig. 4.3 Fig. 4.3

Geometry generator: Prepare Prepare Prepare pagePrepare

The part boundary of the remaining tool geometry (without binder) is shown as a blue line in the main display.

Fig. 4.4 Fig. 4.4 Fig. 4.4 Fig. 4.4

Representation of the part boundary User interface

User interface User interface

User interface Model > Input generator ... > Simulation type: OneStep > OK AFOS Input generator

AFOS Input generator AFOS Input generator AFOS Input generator

Geometry > Type > Full tool (1-Step)

The pre–defined OS boundary has to be deleted.

Delete > Autoform - Question: Delete the current OS boundary line? > Delete

ToolTool ToolTool

The surfaces saved in the Part and the Binder registers are used to automatically define the tool geometry.

Definition of the OS boundary Definition of the OS boundary Definition of the OS boundary Definition of the OS boundary

This line represents the outer edge of the stamped part. Again, this may be defined as dependent upon the punch opening line.

Dependent ... > Bndry (Pre) 1 > OK > Edit … > Curve editor > Glo-bal mod > Expand: 40 > OK

Definition of the OS punch opening Definition of the OS punch openingDefinition of the OS punch opening Definition of the OS punch opening

The punch opening line may be defined as dependent upon as part boundary.

Dependent ... > Bndry (Pre) 1 > OK

Fig. 4.5 Fig. 4.5 Fig. 4.5 Fig. 4.5

AFOS Input generator: GeometryGeometryGeometryGeometry page

Fig. 4.6 Fig. 4.6 Fig. 4.6 Fig. 4.6

OS boundary OS boundary OS boundary

OS boundary and OS punch openingOS punch openingOS punch openingOS punch opening Blank

Blank Blank

Blank Define the sheet thickness:

Thickness: 1.0

Select the following material:

Material: Import... > Steel_General+Europe: if18_1.mat > OK Define the weld line now:

Add weld... > Weld line > Input ...

Fig. 4.7 Fig. 4.7 Fig. 4.7 Fig. 4.7

WeldWeldWeld

Weld dialog

The Curve editor is opened. Define the weld line by entering two points (x = 0/0, y = 200/-200). The start and end point of the weld line are positioned on the OS boundary.

NoteNoteNote

Note: To create a vertical line, press the ShiftShiftShiftShift key when setting the end point of the weld line.

Fig. 4.8 Fig. 4.8 Fig. 4.8 Fig. 4.8

Definition of the weld line position

Following the definition of the weld line, specify a new sheet thick-ness value, and then select the side of the defined weld line where the new thickness value applies (Weld dialog):

Thickness: 1.5

Properties apply at > Click

Fig. 4.9 Fig. 4.9 Fig. 4.9 Fig. 4.9

Definition of area in the sheet with changed material properties Using the right mouse button, click at the right side of the weld line to which the new thickness will apply.

Finalize the weld line definition in the Weld dialog by clicking on OK

LubeLube

LubeLube Lubrication > Constant > Constant > Standard: 0.15 Process

Process Process

Process As you are preparing a Full tool OneStep simulation, it makes sense to define a binder pressure or binder force.

Holding condition > Type: > Binder pressure > Pressure: 6 >

Binder stiffness: 50

Fig. 4.10 Fig. 4.10 Fig. 4.10 Fig. 4.10

Process ProcessProcess Process page

Leave the default settings on the Control page unchanged and start the simulation in the AFOS input generator.

Job > Start simulation ... > Save > Start job: Start

After simulation is completed, the results may be viewed and eval-uated in the AutoForm–User Interface by reopening the simulation file:

User interface User interface User interface User interface File > Reopen

Select the result variable Thickness.

Fig. 4.11 Fig. 4.11 Fig. 4.11 Fig. 4.11

Distribution of thickness

Click on the button for the developed blank :

Fig. 4.12 Fig. 4.12 Fig. 4.12 Fig. 4.12

Developed blank Developed blankDeveloped blank Developed blank

You realize that the original linear weld line has moved during the forming process. It is the objective now to keep the weld line posi-tion as it is and to optimize the weld line posiposi-tion in such a way that the original blank can be formed with a linear weld line.

To achieve the objective, define material marks at both ends of the weld line on the developed blank.

User interface User interface User interface User interface Results > Material marks ... > Set marks

Fig. 4.13 Fig. 4.13 Fig. 4.13 Fig. 4.13

Coordinates of the material marks

Define the two material marks as material line. Internally additional material marks are added along the material line.

AutoForm - Material marks > Define > Material line

Click on the button Formed Sheet in the lower left area of the Auto-Form–User Interface and display the originally defined weld line.

Display > Lines ... > Weld 1 > Dismiss

You can judge from the material lines if the warped position within the part is still acceptable and if the weld line is still in the correct position.

Fig. 4.14 Fig. 4.14 Fig. 4.14 Fig. 4.14

Different weld line positions

Use the material line on the formed part as weld line for another simulation. For this purpose export the material line:

User interface User interface User interface User interface Results > Material lines ... > Material line 1 > File > Write selected

to file … > AF Poly3D > CLOSED polylines: No > weldnew.af >

OK > Material lines > File > Dismiss Save the simulation under another name:

User interface User interface User interface User interface File > Save as > os_lesson_4b.sim > OK

Open the AFOS Input generator again.

Model > Input generator ...

Edit the weld line position on the Blank page by importing the stored material line as new weld line.

Symmetry-planes/welds/holes > Edit ... > Import ... > Delete > For-mat: af > OK > weldnew.af > OK > curve 1 > OK > OK

Start the simulation and check whether a linear weld line is avail-able in the developed blank.

Fig. 4.15 Fig. 4.15 Fig. 4.15 Fig. 4.15

Optimized weld line on the developed blank

4. 5 4. 5 4. 5

4. 5 Lesson 5: Full tool (2-step) Simulation Lesson 5: Full tool (2-step) Simulation Lesson 5: Full tool (2-step) Simulation Lesson 5: Full tool (2-step) Simulation

This lesson is based on a prepared simulation file. The tool contained in this file has been generated with AutoForm–DieDesigner. Objective of this lesson is the definition of symmetry conditions and drawbeads. In addition, we will also show how to optimize the initial blank.

Fig. 5.1 Fig. 5.1 Fig. 5.1 Fig. 5.1

Tool geometry