DYNAFORM 5.7.3 Training TutorialDYNAFORM 5.7.3 Training Tutorial

Descriptions for tipping, generating boundary lines binder and generating corner addendum by using Roof Bow, plus incremental analysis with Inc solver.

1. Click button to create a new database.

2. Click File menu and select Save as ….

3. Enter the file name roofbow_(user name)_(date).df.

4. Click Save button to save the database.

I. Create and Save Database

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1. Click DFE menu (See Figure 1).

2. Select Preparation.

3. Click IMPORT button.

4. Select file location: …/Tutorial2_RoofBow

5. Select file: roof_bow.igs

6. Click OK to import part geometry.

II. Import Geometry

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Figure 1

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Figure 2 Figure 3

II. Import Geometry

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III. Rename Part

Figure 4 Figure 5

1. Select the imported part DIEPART in the Die Tool list.

2. Click Rename (See Figure 4).

3. Enter the new name ROOFBOW in the New Name input box.

4. Click Apply after modification.

Figure 6

1. Select menu DFE Preparation

2. Click Surface Mesh (See Figure 7)

3. Click Select Surfaces and click Displayed Surf. in the opened window to select all the surfaces displayed on the screen (See Figure 8).

4. Toggle on Exclude option (See Figure 9).

5. Select binder surfaces on the screen to remove the surfaces on the part flange (See Figure 10).

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 (See Figure 11).

11. Click Exit to exit the Surface Mesh dialog box.

12. Save the database.

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IV. Auto Mesh Surface

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Figure 7 Figure 8

Figure 9

9 Figure 11 Figure 10

Remove four surfaces on the part.

1. Select DFE Preparation Model Check/Repair (See Figure 12).

2. Click Boundary Display icon (line one, column two) (See Figure 13).

3. Click (Clear highlight) to remove the highlighted boundary line.

4. Click Plate Normal icon (line two, column two).

5. Check the message prompt window to make sure that all elements normal is

consistent.

6. Click Auto Plate Normal icon and click Cursor Pick Part in the displayed menu

to select a mesh on the part (See Figure 14).

7. The normal direction of this mesh will be displayed in the 3D view. In the

displayed dialog box, select Yes to accept that all the normal directions are

upward (if the directions are downward, select No so that the program will

correct all the directions.) (See Figure 15).

8. Click Exit to exit Auto Plate Normal dialog box.

9. Click OK to exit Model Check dialog box. 10

V. Check and Repair Mesh

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Figure 14

Figure 13 Figure 15

Figure 12

V. Check and Repair Mesh

1. Select TIPPING from DFE / preparation menu (See Figure 16).

2. Toggle on Undercut to view the red region (severe) on the part, which indicates

the incapability of draw forming (See Figure 17).

3. Key in 90 in the input box next to step and select x axis as the rotation axis.

4. Click to rotate the tool Die 90 degrees about x axis (See Figure 18). Then the

parts turn to green, which indicates that draw forming is available (See Figure

18).

5. The program will automatically add this tipping operation to the Process Record

list (See Figure 19). (Note: the system will automatically record every tipping

operation in the Process Record list. The user may import, export, combine,

recalculate and delete the tipping information.)

6. Click Exit to exit the Tipping dialog box.

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VI. Tipping

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Figure 17

Figure 16

VI. Tipping

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Figure 18Figure 19

VI. Tipping

1. Click to display the isometric view.2. Click DFE menu and select Binder.3. In the opened dialog box, select the fourth binder type: Boundary Lines Binder4. Key in Binder Size Margin: 100.00 (mm)5. Click Define Binder Orientation.6. Click the Middle Mouse Button to accept the default binder direction (Note:

press the left mouse button and move it on the screen to change the binder direction. Double click the left mouse button to return to the default direction.)

7. Click Create Boundary Lines to create boundary lines of parts (See Figure 20).8. Click Select Boundary Lines (See Figure 22) to select boundary line (See

Figure 23).9. Click OK to accept the selected boundary lines.10. Click Apply to generate binder. The letter color of Create turns from red to

black (See Figure 24). (Note: If the generation of binder is prompted to be failed, please pay attention to the defined Binder Orientation. Please point the thick line to the main curvature direction of the binder.)

11. Click Mesh to mesh binder.12. Key in the Max. and Min. Size of elements: 20.00 and 5 (mm)13. Click OK to confirm (See Figure 25).14. Click Exit to exit the Binder dialog box.15. Save the database.

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VII. Create Boundary Lines Binder

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Figure 20

Figure 21

VII. Create Boundary Lines Binder

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Figure 23

Figure 22

Select two boundary lines on part flange

VII. Create Boundary Lines Binder

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Figure 24

Figure 25

VII. Create Boundary Lines Binder

1. Click DFE menu.

2. Select Addendum and open Addendum dialog box.

3. Click New (Master Profiles group) (See Figure 26).

4. Select the Profile Type: 2 (See Figure 27).

5. Key in Die Radius: 6.0 (mm)

6. Drag the horizontal binder line to the position of -20. Drag the vertical punch outline to the left until it reaches the minimum position where Bar Width =0.

7. Click Apply button.

8. Click Ok to exit the Master Profile dialog box.

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VIII. Create Master Profile

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Figure 26

Figure 27

VIII. Create Master Profile

Binder line

Punch outline

1. Click Assign button in the Addendum group (See Figure 28).

2. Toggle on By Segment option (See Figure 29).

3. Click Select Region button.

4. Select two nodes on part boundary as starting node and ending node for addendum (See Figure 30).

5. Click Yes to accept the marked region.

6. Click Apply.

7. Repeat steps (3) to (6) to insert addendum for the other end.

8. Click Close to exit Assign addendum dialog box.

9. See Figure 32.

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IX. Create Addendum

Figure 29

Figure 28

Select boundary region

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Figure 32Figure 30

Figure 31

IX. Create Addendum

1. Click Assign (Addendum) (See Figure 33).2. Toggle on Corner option.3. Click Select Boundary (See Figure 34).4. Select boundary profiles of addendum (See

Figure 35).5. Select two nodes on the part boundary (See

Figure 35).6. Click Yes to accept the defined region.7. Click Apply.8. Click Yes to accept the result.9. Repeat steps (3) to (8) to complete the other

three addendum and addendum between parts.10. Click Close to exit Assign Insert Addendum

dialog box.

Note: when generating surfaces automatically via Type Corner and modifying their connected addendum, the addendum for Corner must be re-generated.

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X. Create Corner Addendum

Figure 34

Figure 33

1. Click Generate to create addendum surface.2. Click Close to exit Addendum Generation dialog box. 3. See Figure 36.4. Save the database.

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XI. Create Addendum Surface

Select corner region

Create Corner addendum

Before generating surfaces

After generating surfaces

Boundary profileTwo nodes on part

25Figure 36Figure 35

XI. Create Addendum Surface

1. Click DFE.

2. Select Modification.

3. Select BINDER TRIM (See Figure 37).

4. Click Select icon (See Figure 38).

5. Toggle off surfaces.

6. Select POP and Die Edge lines on the screen (See Figure 39).

7. Click OK to confirm the selection.

8. Click Apply.

9. Click Close to exit Binder Trim dialog box.

10. Save the database.

11. Toggle off all parts and then toggle on C_BINDER part (See Figure 40).

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XII. Binder Trim

Figure 38

Figure 37

Binder trim line Binder after trimming

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Figure 40Figure 39

XII. Binder Trim

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 Generator2. Select Create Line3. Select pick the corner location of the blank

1. Click Blank Generator2. Select Create Line3. Select pick the corner location of the blank

Mesh the Blank

1. Click Boundary Line2. Select the blank outline3. Enter 20 for blank element size

1. Click Boundary Line2. Select the blank outline3. Enter 20 for blank element size

Mesh the Blank

Click Yes to accept the meshClick Yes to accept the mesh

Blank MeshBlank Mesh

Setting up Formability

Select “DFE/Formability”

Setting up Formability

1. Select Single action2. Select Upper Tool Available3. Select Blank

1. Select Single action2. Select Upper Tool Available3. Select Blank

Define Blank

1. Click Select Part

2. Select Add

3. Select Blank Part

Select Blank Material

Select Blank Material as DQSelect 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: roofbow.iges

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