DFE Training INC Tutorial 4 DoorInner En

8/13/2019 DFE Training INC Tutorial 4 DoorInner En

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DYNAFORM 5.7.3 Training Tutorial


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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.


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1. Click to create a new database.

2. Click File menu and select Saveasbutton.

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

4. ClickSaveto save the database.

I. Create and Save database

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1. Click DFE(See Figure 1).

2. SelectPreparation.

3. Click IMPORTbutton in Definepage.

4. Select file location: /Tutorial4_DoorInner

5. Select file:door_inr.igs

6. ClickOkbutton to import part geometry.

II. Import Part Geometry

Figure 1

4


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Figure 2

Figure 3

5

II. Import Part Geometry


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III. Rename Part

6

1. Select the imported part DIEPARTin the Die Toollist.

2. Click Rename(See Figure 4).3. Enter the new name DOORINNin the input box for New Name.

4. ClickApply after modification.

Figure 4Figure 5


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1. Select DFEPreparation

2. ClickSurface Mesh(See Figure 6) and click Select Surf acein the displayedSurface Meshwindow(See Figure 7).

3. ClickDisplayedSurf.button to select all the surfaces displayed on screen

(See Figure 8).

4. Toggle onExclude(See Figure 8).

5. Select flange surfaces on screen (These surfaces cannot be formed duringdrawing, so they should be removed during drawing) (See Figure 9).

6. Click OKto confirm the selected surfaces.

7. Return toSurface Meshwindow.

8. Key in the Max. Size: 20.00(mm)

9. ClickApp lyto mesh.10. Click Yesto accept mesh.

11. Click Exitto exit the Surface Mesh dialog box.

12. See Figure 10.

13. Click to save the database.

IV. Auto-mesh Surfaces

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8

Figure 6

Figure 7

Figure 8


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9Figure 10Figure 9

IV. Auto-mesh Surfaces

Remove flange surface


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1. select DFEPreparationModel Check/Repair(See Figure 11).

2. Click Boundary Displayicon (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 Norm alicon (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 buttonAuto plate normalin the first line (See Figure 13).

7. Select Cursor Pick Partin 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 Exitto exitAuto plate normalmenu.

11. Click OK to exit Model Check/Repairmenu.

V. Check and Repair Mesh

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11

Figure 12

Figure 11



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12

Figure 13

Figure 16

Figure 15Figure 14



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1. Select TIPPINGfrom 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 (counter-clockwise).

7. The system will automatically record this tipping information in the Process Record list. The part

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 (counter-clockwise).

10. At present, the top view for part is shown in Figure 19.b.

11. The system will automatically record the second tipping information in the Process Record list.

12. Click Exit to exit Tipping dialog box.

VI. Tipping

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14

Figure 17(a)(b)

VI. Tipping


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15Figure 18

(a)

(b)

VI. Tipping


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16Figure 19(a)

(b)

VI. Tipping


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VII. Inner Fill

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1. Click DFE PREPARATIONBou ndary Fi ll Inn er Fil l2. Select the first iconAuto Fill(See Figure 20.a).

3. Enter Holein the input box of To Part, which means to put the generated

filled holes to Hole part.

4. Click applyto 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 tocancel all the holes, as illustrated in Figure 20.b and 20.c). The inner

holes will be filled automatically.

5. ClickCloseto exit INNER FILLdialog box.6. Click to show the top view.

7. See Figure 21.


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18

Figure20

(a)

(b)

(c)

VII. Inner Fill


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abefore inner fill bafter inner fill

Figure 21

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VII. Inner Fill


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VIII. Outer Smooth

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1. Click DFE PREPARATIONBou ndary Fil lOut Smooth2. Click Select partand selecthoodinn(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 Boundaryto fill.7. Click Exitto exit Outer Smooth dialog box.8. Repeat the above step VII to check and repair mesh.

9. See Figure 23.


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21Figure 22

(a)(b)

(c)

VIII. Outer Smooth


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Result after boundary smooth

Figure 23

1

22

Delete some elements by manual.

VIII. Outer Smooth


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1. Click BinderinDFEmenu.2. Select Binder Type: Flat Binder(See Figure 24.a).

3. Key in Binder Margin: 400.00(mm)

4. Key in shift: 20.00(mm)

5. Click App lyto 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 Modifyto modify the binder. Switch to top view.

8. Click Addto add a section. Toggle on By inputand key in: dx=0dy=0(See

Figure 25.a).

9. Click vectorto define section direction. Click uin the displayed window and u=1,

which means the section is along X axis (See Figure 25.b). Click OKto confirm.10. Return to Modify. Click createto add a section cntrl ln:0, which passes through

the origin and is parallel to X axis, to control lineslist box (See Figure 26).(to be

continued)

IX. Create and Modify Binder

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24

Figure 24

(a)

(b)



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25

Figure 25

(a)(b)



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26

Figure 26

(a)

(b)



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continued

11. Click Addto add another section along Y axis. Toggle onBy Inputand 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 alongYaxis (See Figure 27.b). ClickOKto

confirm.

13. Return toModifypage and clickcreatebutton to add a section cntrl ln:1,

which passes through (500,0)(relative to process base point) and is parallel

to Y axis, tocontrol lineslist box (See Figure 28).

14. Select the first section cntrl ln:0 incontrol lineslist box and clickEdit(See

Figure 28).

15. The program pops up the2d curvewindow for section modification. Click

to switch to front view of part, which is convenient for viewing during

modification of control lines.

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28

Figure 27

(a)(b)



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29

Figure 28

(a)(b)



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30

Figure 29

(a)

(b)



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continued

16. Select the left line segment in2d curvewindow and clickStraight to define it as straight line;

then, select the right line segment and clickStraight to define it as straight line (See Figure 30).

17. Hold Shiftkey and use the left mouse button to add a control point near the intersection of the

left line segment andY0 line (See Figure 31). At present, there are four control points on the

section alongXaxis:A,D,C,B(from left to right).

18. Adjust the coordinates for four control points in sequence. The z values for pointsA, B, C , D

are 80, 160,10 ,-100. Key in the fillet radiusr=1300after pointDis selected (See Figure 31.b).

19. At present, the front view is shown as Figure 32.

20. ClickApplyto accept the current profile operation and clickCloseto exit2d curvewindow.

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. ClickApp lyto change the binder from flat to single surface.

23. Return toBindercreatepage and click Mesh to mesh binder. The Max. and Min. Size are50

5. Then the operation for Create and Modify Binder is completed (See Figure 33).

24. ClickExi t to exit binderwindow.

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Figure 30(a) (b)

32


Select the left line segment Select the right line segment


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Figure 31

(a) (b)

33


A D C B

Add a control point here


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34

Figure 32



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35

Figure 33



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X. Create Master Profile

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1. Click DFE.

2. SelectAddendum.3. Select Newin 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 Okto exit Master Profiles dialog window (See Figure 34.c).

6. ClickNewto 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. ClickOkto exit Master Profiles dialog window.


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37Figure 34(a)

(b) (c)



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38Figure 35(a) (b) (c)



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XI. Create Addendum

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1. Select Master 1(type1)as the master profile to create addendum.

2. ClickAssign (Addendum)(See Figure 36.a).3. Select Addendum Type:Outer(See Figure 36.b).

4. Toggle onBy Segmentand clickSelect Regionto 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 verticalflange (See Figure 37).

6. ClickYesto confirm the selected region. ClickApp lyto generate addendum.

ClickCloseto exit.

7. Then selectMaster 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 App lyto generate addendum (See Figure 38).


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40

Figure 36(a)

(b)

(c)Starting point of vertical flange

End point of vertical flange

XI. Create Addendum


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41

Starting point A of addendum

Endpoint B of addendum

Figure 37

(a)

(b)

(c)

XI. Create Addendum


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Figure 38 42

XI. Create Addendum


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1. Click ModifyunderAddendum (See Figure 39.a).

2. SelectSmoothand POP line(See Figure 39.b).3. ClickApp lyand 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. SelectThrough Fixed Points(See Figure 39.c).

5. Use the rotation and zooming button to check the region as shown in

Figure 40.6. ClickSelectFixedPointsand select four points on addendum (See

Figure 40).

7. ClickPreviewto preview the modifiedpop line.

8. Click App ly.

9. ClickOK.10. Repeat steps 2 to 9 to smooth 2, 3, 4 (to be continued).

XII. Smooth Addendum

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44

Figure 39

(a) (b)

(c)



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Fi ure 40

45


P4

P3

P2

P1

POP line after

smooth

POP line before smooth


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11. Click Closeto close Smooth Addendum dialog box.

12. Delete the profile between two points marked in region5 (See Figure 41).

13. Click OKto confirm deletion (See Figure 41).

1

2

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1

2


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1

2 34

Figure 41

5

47



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1. Click Generate(See Figure 42.a)

2. Select POP Line, Profile Line, AddendumSurface and clickApp lyto generate

addendum surface automatically (See

Figure 42.b).

3. Click Closeto exit and save the

database.

Figure 42

Before generating surfaceAfter generating surface

XIII. Create Addendum Surface

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(a) (b)


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XIV. Binder Trim

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1. Click DFEModification(See Figure 43.a).

2. SelectBINDERTRIM(See Figure 43.b).3. Select Binder Type:Outer

4. Toggle offSurface.

5. ClickSelect(See Figure 43.c).

6. Select Trim Line (See Figure 43.d).

7. ClickOkto confirm.8. ClickApp ly.

9. ClickYesto accept the displayed line.

10. ClickCloseto exit Binder Trim dialog window.

11. Click to show the top view.

12. Toggle off all the parts exceptC_BINDER(See Figure 43.e).13. ClickCloseto exitMODIFICATIONdialog box.14. Toggle onSurface.

15. Save the database.


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Figure 43

(a)

(b)

(c)

(d) (e)

Binder trim line

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XIV. Binder Trim


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1. Click DFE.

2. SelectPreparation.3. Select Unfold Flange(See Figure 44).4. 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. ClickOKto 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 Exitto exit DFE Preparationdialog box.

13. Save the database.

XV. Unfold Flange and Create Trim Line

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Figure 44


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52

Figure 45

(b)

(c)

(a)

(d)

(e)

XV. Unfold Flange and Create Trim Line

i i l d i f h l i


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Die Face Design completed, setting up for the analysis

Build a Blank


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Build a Blank

1. ClickParts.

2. Select Create

3. Type Blankin the Name.

Mesh the Blank


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Mesh the Blank

1. Click Blank Generator

2. Select Create Lin e

3. Select pick th e corner locat ion of

the blank

Mesh the Blank


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Mesh the Blank

1. Click Bound ary L ine

2. Select the blank ou t l ine

3. Enter 20for blank element size

Mesh the Blank


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Mesh the Blank

Click Yesto accept the mesh

Blank Mesh

Setting up Formability


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Select DFE/Formability



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1. Select Singleact ion

2. Select Upper Too l

Avai lable

3. Select Blank

Define Blank


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Define Blank

1. Click Select Part

2. Select Add

3. Select Blank Part

Select Blank Material


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Select Blank Material

Select Blan k Material

as DQ



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1. Click Apply

2. Select Preview

3. Select Submi t job

Submit the Job


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Submit the Job

Thickness Contour Plot


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Thickness Contour Plot

Forming Limit Diagram


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Forming Limit Diagram

Input file information


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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 [email protected]

Documents

DFE Training INC Tutorial 4 DoorInner En