DYNAFORM 5.7.

3 Training Tutorial

Descriptions for Inner Fill, Symmetry, Outer Smooth, Flat Binder and Unfold Flange, etc. by using Hood Inner, plus incremental analysis with Inc solver.

I. Create and save database

1. 2. 3. 4. Click to create a new database. Click File menu and select Save as. Enter the file name: Hoodinner_(user name)_(date).df Click Save to save the database.

II. Import Part Geometry

1. 2. 3. 4. 5. 6. Click DFE menu (See Figure 1). Select Preparation. Click IMPORT button on Define page. Select file location: /Tutorial3_HoodInner Select file: hood_inner.igs 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 DIE PART in Die Tool list. Click Rename (See Figure 4). Enter the new name HOODINN. Click Apply after modification.

Figure 5 Figure 4

IV. Auto-mesh surfaces

1. Select DFE Preparation 2. Click Surface Mesh (See Figure 6) and click Select Surfaces (See Figure7) in surface Mesh window. 3. Click Displayed Surf. button to select all the surfaces displayed on the screen (See Figure 8). 4. Toggle on Exclude option (See Figure 8). 5. Select flange surfaces on the screen (because these surfaces cannot be formed 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

Exclude flange surfaces

Figure 9

Figure 10

V. Define Symmetry
1. Click DFE PreparationSymmetry/Double Attach. 2. Select Symmetry: Half Symmetry Input (See Figure11). 3. Select x-z plane to define symmetry type. 4. Click Select Point(s) to define symmetry plane. 5. Select a node as shown in Figure 12. 6. Change the value of Align Nodes to 0.5, and click Align Nodes button. Select Yes in the displayed window (See Figure 13). 7. Click Mirror Geometry to mirror the other half of part. 8. Click Exit to exit Preparation dialog box. 9. Save the database.

Figure 11

10

V. Define Symmetry

13

12

15

14

11

VI. Check and Repair Mesh

Select DFE Preparation Model Check/Repair (See Figure16 and 17). Click Boundary Display icon (line one, column two) (See Figure 18). Click (Clear highlight) button to remove the highlighted boundary lines. Click Plate Normal icon (line two, column two). Check the message prompt window to make sure that all element normal is consistent. 6. Click OK to exit Model Check dialog window. 1. 2. 3. 4. 5.

12

VI. Check and Repair Mesh

Figure 17 Figure 16

13

VI. Check and Repair Mesh

Figure 18

14

VII. Tipping
1. Select TIPPING from DFE / Preparation.

2. Toggle on Undercut (See Figure 19).

3. The parts are all green as shown in Figure 20, so the stamping directions do not need to be adjusted. 4. Click Exit to exit Tipping dialog window.

15

VII. Tipping

Figure 20

Figure 19

16

VIII. Inner Fill

1. Click DFE PREPARATIONBoundary FillInner Fill 2. Select the first icon Auto Fill (See Figure 21). 3. Enter Hole in the input box of To Part, which means to put the filled holes in 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 22 and 23). 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 24 and 25.

17

VIII. Inner Fill

Figure 22

Figure 23 Figure 21

18

VIII. Inner Fill

Before inner fill

Figure 24

After inner fill

Figure 25

19

IX. Outer Smooth

1. Click DFE PREPARATIONBoundary FillOut Smooth
2. Click Select part and select hoodinn (See Figure 26 and 27). 3. Select the first button Roller, and the system will automatically enter HOO_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 the Outer Smooth dialog box.

8. Repeat step VII to check and repair mesh. 9. See Figure 29.

20

IX. Outer Smooth

Figure 27 Figure 26 Figure 28

21

IX. Outer Smooth

The result after outer smooth

Figure 29

22

X. Create Binder
1. Click Binder from DFE menu. 2. Select Binder Type: Two-line Binder (See Figure 30). 3. Key in Binder Margin: 400.00 (mm) 4. Key in shift: 30.00(mm) 5. Click Apply to create binder and the letter color of Create turns from red to black. 6. Click Mesh to mesh the binder. 7. Key in the Max. and Min. Size: 30.00 (mm), 5(mm) (See Figure 31). 8. Click OK to mesh the binder (See Figure 32). 9. Click Exit to exit the Binder dialog box. 10.Save the database.

23

X. Create Binder

Figure 31

Figure 30

Figure 32

24

XI. Create Master Profile

1. Click DFE menu. 2. Select Addendum. 3. Select New in the displayed dialog box to create a new master profile (See Figure 33). 4. Select type: Profile Type 3, PartAngle=45, PO Width=30, Bar Height=-10 (See Figure 34). 5. Click Ok to exit Master Profile dialog box (See Figure 35).

25

XI. Create Master Profile

Figure 33

Figure 34

Figure 35

26

XII. Create Addendum

1. 2. 3. 4. Click Assign button in Addendum group (See Figure 36). Select addendum Type: Outer (See Figure 37). Toggle on By Segment. Click Select Region and select half boundary line of Hoodinner as addendum range (See Figure 38). 5. Click Yes in the displayed dialog box to accept the selected region. 6. Click Apply to generate addendum (See Figure 39). 7. Click Close to exit Addendum dialog box.

Figure 36

Figure 37

27

XII. Create Addendum

Figure 38

Figure 39

28

XIII. Smooth Addendum

1. 2. 3. 4. 5. Click Modify under Addendum (See Figure 40). Select Smooth and POP line (See Figure 41). Click Apply. Select Through Fixed Points (See Figure 42). Use the rotation and zooming buttons to check the region as shown in Figure 43. 6. Click Select Fixed Points and select four nodes on addendum, as shown in Figure 43. 7. Click Preview. 8. Click Apply. 9. Click OK. 10.Click Close to close Smooth Addendum dialog box.

Figure 40

Figure 42

Figure 41

29

XIII. Smooth Addendum

P1 P2

Smoothed POP line

POP line before smooth
Figure 43

P3

P4 30

XIV. Mirror Addendum

1. 2. 3. 4. Click Copy under Addendum (See Figure 44). Select Mirror in the displayed dialog box (See Figure 45). Click Apply. The addendum to be mirrored and the mirrored boundary will be highlighted automatically (See Figure 47). 5. Select Yes in the displayed dialog box (See Figure 46). 6. The other half of addendum will be mirrored automatically (See Figure 48). 7. Click close to exit Copy Addendum dialog box.

Figure 45 Figure 44

Figure 46

31

XIV. Mirror Addendum

Figure 47

Figure 48

32

XV. Create Addendum Surface

1. Click Generate (See Figure 49). 2. Select POP Line, Profile Line, Addendum Surface and click Apply to generate addendum surface automatically (See Figure 50). 3. Click Close to exit and save the database.
Figure 49 Figure 50

Before create surface

After create surface

33

XVI. Binder Trim

1. Click DFE Modification (See Figure 51). 2. Select BINDER TRIM (See Figure 52). 3. Select binder type: Outer 4. Toggle off Surface. 5. Click Select (See Figure 53). 6. Select trim line (See Figure 54). 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 55). 13.Click Close to exit MODIFICATION dialog box. 14.Toggle on Surface. 15.Click to save the database.
34

XVI. Binder Trim

Figure 51

Binder Trim Line

Figure 54

Figure 53

Binder after trimming

Figure 52
Figure 55

35

XVII. Unfold Flange and Create Trim Line

1. 2. 3. 4. Click DFE. Select Preparation. Select Unfold Flange (See Figure 56). Use rotation and zooming tools to view the region as shown in Figure 57. 5. Select the flange surface to be unfolded as shown in Figure 57. 6. Click OK to confirm. 7. Select Accept in the displayed window to calculate the flange line automatically. 8. Type in the bending angle: 0 9. Click OK to confirm. 10.The system will automatically unfold the surface to the addendum (See Figure 60) to achieve the unfolded surface. 11.Click DONE to exit. 12.Repeat (3) to (11) to unfold other flange surfaces. 13.Click Exit to exit DFE Preparation dialog box. 14.Save the database.

Figure 56

36

XVII. Unfold Flange and Create Trim Line

Figure 58

Select flange surfaces

Figure 57

Calculate base line

Figure 59

Unfolded flange surface

Figure 60

37

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