AutoForm Trim

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ALGHAFORM PAYLASIMIDIR

www.forum.alghaform.com

iletisim: [email protected]

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5555 AutoForm–Trim

AutoForm–Trim

AutoForm–Trim is a module to determine either a blank outline or a cut contour outline in connection with the AutoForm–Incremental solver so that the part reaches the defined target boundary at the end of the forming process. Use AutoForm–Trim for the following typical cases:

• Calculation of the customized blank sheet for crash form-ing parts

• Calculation of the customized blank sheet for a predefined target boundary of a drawing part

• Calculation of the final cut contour in areas in which addi-tional forming steps follow (e.g. second forming, bending operation, flanging operation)

Pre–condition for the calculation of the blank outline and the cut contour is a simulation with AutoForm–Incremental containing all necessary forming and cutting operations. Basing on this simulation you define parameters for the calculation of the blank outline and the cut contour.

The parameters for the calculation of a blank outline are the target boundary of the part and the forming process after which the target boundary has to be reached. Subsequently the outline of the initial blank is modified iteratively by the simulation of all necessary forming operations until the part has reached the target boundary at the end of the forming process.

For the calculation of a cut contour with AutoForm–Trim you need the following input:

• Cut contour to be optimized • Target boundary for the part

• Forming process after which the target boundary has been reached

Subsequently the contour of the defined cut is modified iteratively by the simulation of all necessary forming operations until the part has reached the target boundary at the end of the forming process. www.alghaform.com

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The accuracy of the calculation of the blank outline and the cut con-tour depends on the chordal deviation of the FEA model for the tools and the part.

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Contents of the Workshop „AutoForm–Trim“

Lesson1

Lesson1 Lesson1

Lesson1 Blank outline optimizationBlank outline optimizationBlank outline optimizationBlank outline optimization . . . .. . . .. . . .. . . .4444

Lesson 2 Lesson 2 Lesson 2

Lesson 2 Optimization of a trimming cut outlineOptimization of a trimming cut outlineOptimization of a trimming cut outlineOptimization of a trimming cut outline . . . .. . . .. . . .11. . . .111111

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5. 1

5. 1 Lesson 1: Blank outline optimization

Lesson 1: Blank outline optimization

The following example shows how to use AutoForm–Trim in order to optimize a blank outline.

The following files are needed to run the example:

• tr_lesson_01_basis.sim: The simulation with the blank outline to optimize

• tr_lesson_01_target.igs: The final outline

The simulation

Open the sim file tr_lesson_01_basis.sim

File > Open ... > Select a file > Files: tr_lesson_01_basis.sim > OK

Fig. 1.1 Fig. 1.1 Fig. 1.1 Fig. 1.1

The initial geometry

Trim calculation

Open the Input generator and create Trim:

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Lesson 1: Blank outline optimization

Fig. 1.2 Fig. 1.2 Fig. 1.2 Fig. 1.2

Create TrimTrimTrimTrim

Then you’ve got a new page in the Input generator called Trim. Fig. 1.3

Fig. 1.3 Fig. 1.3 Fig. 1.3

The TrimTrimTrim page in the Input generatorTrim

On the Trim page, select the option Optimize blank outline: Trim

Trim Trim

Trim Optimization type > Optimize blank outline

Target process step: Process step where you want to get the final

part with the correct outline.

Target process step: drawing which corresponds to the process step where we want to get the correct outline at the end of the step.

Target Boundary: To give the correct target outline.

We must give the final outline we want to get at the end of the tar-get process step.

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Trim Trim Trim Trim

Target boundary > Import > IGES > tr_lesson_01_target.igs >

Curve 1 and Curve 2 > OK

(To select both Curve 1 and 2, first select curve 1 and then select curve 2 while pressing the Ctrl key)

Max # of iterations: 5

We have to define the maximum number of iterations (maximum number of simulations)

Max deviation: 1.2

We have to define the maximum deviation (mm) of the cutting con-tour from the target boundary.

Fig. 1.4 Fig. 1.4 Fig. 1.4 Fig. 1.4

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Lesson 1: Blank outline optimization

Fig. 1.5 Fig. 1.5 Fig. 1.5 Fig. 1.5

The TrimTrimTrim page at the end of the inputTrim Now you can launch the Trim calculation:

File > Save as … > tr_lesson_01.trm

Job > Start trim > Save > Start Fig. 1.6 Fig. 1.6 Fig. 1.6 Fig. 1.6 Start trim Start trim Start trim Start trim

In this example, you’ve got the correct result in just 2 iterations.

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Trim results management

AutoForm saves in the trim file (tr_lesson_01_basis.trm) the infor-mations concerning the different iterations it has made, and it cre-ates files for each iteration of the Trim modulus

(tr_lesson_01_basis_trm1.sim, tr_lesson_01_basis_trm2.sim etc.). Open the file tr_lesson_01_basis.trm to open the Trim manager:

User interface User interface User interface User interface

File > Open trim ... > Select a file > Files:tr_lesson_01.trm

Fig. 1.7 Fig. 1.7 Fig. 1.7 Fig. 1.7

The Trim managerTrim managerTrim manager; open simulation 2222Trim manager You get access to the following functions:

• Convergence … allows you to check the convergence for each simulation and then choose the best one.

• Open allows you to choose which simulation you want to open, the basis simulation or one of the trim simulation. Then you can choose the simulation you want to open (generally the last one) and then export the optimized cut contour.

In order to do so, open the curve manager, select the contour you want to export and export it.

User interface User interface User interface User interface

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Lesson 1: Blank outline optimization

Fig. 1.8 Fig. 1.8 Fig. 1.8 Fig. 1.8

Export with the curve manager Fig. 1.9

Fig. 1.9 Fig. 1.9 Fig. 1.9

Blank outline, target boundary and part at the beginning of the cal-culation of the blank outline with AutoForm–Trim

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Fig. 1.10 Fig. 1.10 Fig. 1.10 Fig. 1.10

Blank outline, target boundary and part after the calculation of the blank outline with AutoForm–Trim

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Lesson 2: Optimization of a trimming cut outline

5. 2

5. 2 Lesson 2: Optimization of a trimming cut outline

Lesson 2: Optimization of a trimming cut outline

The following example shows how to use AutoForm–Trim in order to optimize a trim-ming cut contour.

The following files are needed to run the example:

• tr_lesson_02_basis.sim: The simulation with the cut out-line to optimize

• tr_lesson_02_target.af: The final outline

The Simulation

Open the sim file tr_lesson_02_basis.sim:

File > Open ... > Select a file > Files: tr_lesson_02_basis.sim

Fig. 2.1 Fig. 2.1 Fig. 2.1 Fig. 2.1

The initial geometry

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Trim calculation

Once the simulation is over, open the Input generator and create Trim:

Input generator > Create > Trim

Fig. 2.2 Fig. 2.2 Fig. 2.2 Fig. 2.2

Create TrimTrimTrimTrim

Then you’ve got a new page in the Input generator called Trim.

Fig. 2.3 Fig. 2.3 Fig. 2.3 Fig. 2.3

The TrimTrimTrim page in the Input generatorTrim

On the Trim page, select the option Optimize cut contour:

Trim Trim Trim Trim

Optimization type > Optimize cut contour

Cut process step: to define the cutting process step where you want

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Lesson 2: Optimization of a trimming cut outline

Cut process step > 2_cutting1 which corresponds to the trimming cut operation

Target process step: Process step where you want to get the final

part with the correct outline.

Target process step > 4_abkanten which corresponds to the process step where we want to get the correct outline at the end of the step.

Target Boundary: To give the correct target outline.

We must give the final outline we want to get at the end of the tar-get process step.

Trim Trim Trim

Trim Target boundary > Import > af > Keep orientation >

tr_lesson_02_target.af > Curve 4 > OK

Max # of iterations: 5

We have to define the maximum number of iterations (maximum number of simulations).

Max deviation: 1.2

We have to define the maximum deviation (mm) of the cutting con-tour from the target boundary.

Fig. 2.4 Fig. 2.4 Fig. 2.4 Fig. 2.4

Selection of the target outline

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Fig. 2.5 Fig. 2.5 Fig. 2.5 Fig. 2.5

The TrimTrimTrim page at the end of the inputTrim Now you can launch the Trim calculation:

File > Save as … > tr_lesson_02.trm

Job > Start trim > Save > Start

Fig. 2.6 Fig. 2.6 Fig. 2.6 Fig. 2.6

Start trim Start trimStart trim Start trim

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Lesson 2: Optimization of a trimming cut outline

Trim results management

AutoForm saves in the first sim file (tr_lesson_02_basis.sim) the informations concerning the different iterations it has made, and it creates files for each iteration of the Trim modulus

(tr_lesson_02_basis_trm1.sim, tr_lesson_02_basis_trm2.sim etc.). Open the tr_lesson_02_basis.trm file to open the Trim manager: User interface

User interface User interface

User interface File > Open trim ... > Select a file > Files: tr_lesson_02.trm

Fig. 2.7 Fig. 2.7 Fig. 2.7 Fig. 2.7

The Trim managerTrim managerTrim manager; open simulation 2222Trim manager You get access to the following functions:

• Convergence … allows you to check the convergence for each simulation and then choose the best one.

• Open allows you to choose which simulation you want to open, the basis simulation or one of the trim simulation. Then you can choose the simulation you want to open (generally the last one) and then export the optimized cut contour.

In order to do so, open the curve manager, select the contour you want to export and export it.

User interface User interface User interface

User interface Model > Curve manager > Cut contour 1 > File >Export...

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Fig. 2.8 Fig. 2.8 Fig. 2.8 Fig. 2.8

Export with the Curve manager

Miscellaneous informations concerning the correct

use of the Trim modulus.

Always remember to select the Write Restart option in the Control page of the Input generator for the basis simulation. The Trim mod-ulus uses this restart file and you won’t be able to create a trim without it.

Fig. 2.9 Fig. 2.9 Fig. 2.9 Fig. 2.9

Blank outline, target boundary and part at the beginning of the cal-culation of the cut contour with AutoForm–Trim

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Lesson 2: Optimization of a trimming cut outline

Fig. 2.10 Fig. 2.10 Fig. 2.10 Fig. 2.10

Blank outline, target boundary and part after of the calculation of the cut contour with AutoForm–Trim

In order to be sure of the Trim computation, follow these advice: • It is better to give a realistic initial trimming cut contour or

blank outline.

• Try to make two calculations with two different initial cut contours and then compare the results you get with the two computations. If you get the same results, then you’ve got the correct result.

• Generally, AutoForm–Trim gives the right result in less than 5 iterations.

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