Stamp a Part Perfectly on the Very First Hit.

Transcription

1 Stamp a Part Perfectly on the Very First Hit. Using the right software tool it is possible. DYNAFORM allows you to accurately simulate the stamping of parts to predict formability issues, validate die design, reduce die development time, improve manufacturing efficiency & increase profitability. DYNAFORM is Now Enhanced with Optimization Try DYNAFORM Today

2 Blank Size Engineering (BSE) Blank, Nest & Generate Quotes A quick & easy process to check formability results & estimate manufacturing costs. BSE is a complete solution for accurately estimating blank size along with blank nesting for maximum material utilization, minimum scrap and piece costs. Using streamlined procedures, this powerful module allows the user to predict thinning, thickening, thickness strain, major prin. strain, min prin. strain, strain tensor & generate a forming limit diagram (FLD). BSE is now enhanced with nesting optimization to review all nesting possibilities and to maximize material utilization. BSE also offers enhanced FLD & thickness/thinning contour reporting capabilities. The improved MSTEP offers even more accurate results for the blank outline and trim line. Importable File Types IGES, VDA, DXF, STL, ACIS, LINE DATA, CATIA, NX, PRO-E, STEP, NASTRAN, DYNA, DYNAIN, ABAQUS Part Preparation Separates top & bottom surfaces of solid-model parts Automatically generates middle surfaces Fixes & fills surface gaps & holes Automatically meshes Tips double-attached parts Fills holes & gaps between double-attached parts Blank Development Blank size estimates (accurately predicts flat blank profiles) Supports tailor welded blanks & double attached parts Outputs press direction automatically after running MSTEP Unfolds flanges Trim line calculations Produces the most accurate blank, accounting for linear bends and material stretch during the forming process Supports constraint conditions in the accurate method Nesting Allows nesting with imported, created or MSTEP generated outline Supports outline development, editing & deletion Optimal 1-up, 2-up, 2-pair, mirror & multiple blank nesting Fitted geometry shape nesting: rectangle, parallel, trapezoid, isosceles trapezoid & arc Supports nesting with fixed angle, pitch or width Supports nesting with the range of angle, pitch &width Allows nesting in plate to align the outlines in plate position Calculates material utilization, fall-off & piece cost Calculates 3D trim line of each outline & outputs IGES Outputs 3D trim line in the original position & tipping position for double-attached parts Forming Analysis Generates a forming limit diagram (FLD) Predicts thickness, thinning, thickening & strain Report Generation Cost estimation reports (maximum material utilization & product piece cost) Formability reports (thickness, thinning & FLD) Supports different output units for nesting reports Offers a combined report for tailor welded blanks

3 Formability Simulation (FS) Uncover Design Flaws & Optimize Product Designs Accurate formability results prevent costly manufacturing issues. Formability Limit Diagram This powerful module facilitates the rapid development & validation of both single-station and progressive die designs. FS helps to uncover hidden problem areas and enables designers to optimize designs based on accurate LS-DYNA based forming results. FS is now enhanced with optimization. Engineers now can go beyond identifying problem areas by incorporating design optimization within simulation to improve performance & quality reducing wrinkling, thinning & tearing. FS also now offers improved trim line development. Features Quick & easy set-up Multiple tools & multi-station progressive die simulations User-friendly guided user interface Material Library Standard material types Mild, high strength & stainless steel materials New dual phase steel, aluminum & metallic alloys Functions Superplastic forming, Hot Forming, Hydroforming & Roller Hemming capabilities Springback Analysis & Springback Compensation Tube Bending for multi-stage rotary draw bending simulations Usable Feedback Results Forming Limit Diagram (FLD) indicates problem areas Predict splitting, thinning & wrinkling Springback compensation *LS-DYNA is a trademark of LSTC

4 Formability Simulation (FS) NEW! DYNAFORM FS Add-ons Trim Line Development The Trim Line Development add-on offers multiple stage trim line development simulation capabilities. It uses an iterative approach for simulating trimming during metal stamping, which ensures that final trim line result matches the target line. Hot Forming Hot Forming Simulations are also now possible with DYNAFORM. Using this add-on, the hot forming process can be simulated, while the user can accurately predict the result under different blank and tool temperatures. Multiple Stage Trim Line Results Heat transfer from blank to tool is proportional to the temperature gradient of the contact partners. Rotary Tube Bending The Rotary Tube Bending add-on allows the user to calculate the tube (product) centerline, generate the bending process automatically, edit, review and analyze the bending process through simulation. The user can also preview the tools movement through the bending process via the simulation. Die Structure Cooling The Die Structure Cooling Add-on, implemented in a special version of ETA s PreSys software environment, uses tetra mesh generation plus a transient thermal solver showing the temperature history during stamping cycles. Cooling Channels Tube Blank, Tools & Process Simulation Finite Element Model of Die & Blank

5 Die System Analysis (DSA) Analyze Die System Operations Develop & design a formable part more quickly than ever. Scrap Shedding & Removal The finite element approach to die system design is an efficient way to predict and resolve many stamping related concerns within the die production line. DSA simulations can help to streamline die system design from the analysis of scrap shedding and removal and die structural integrity, to sheet metal transferring and handling. Die Structural Integrity Simulate operational loads Generate FEA models of the die structure Define operational & stamping loads Evaluate die structure strength & durability Implicit & explicit solutions Scrap Shedding & Removal Streamline modeling for scrap, trim dies, chutes & trim steel Create trimming operations & shedding simulations Sheet Metal Transferring & Handling Simulate metal transfer during manufacturing Simulate transfer to die station, between stations & placement of finished piece on shipping rack Predict interference between work-piece & tools Use stress/strain results to prevent damage during transportation, & during loading & unloading operations

6 Optimization Platform (OP) DYNAFORM Enhanced with Optimization Develop & design a formable part more quickly than ever. Before Design Optimization After Design Optimization Optimization of sheet metal forming is now possible using the DYNAFORM Optimization Platform Module (OP). The most accurate die analysis tool available, DYNAFORM is now enhanced with the optimization search engine, SHERPA, from Red Cedar Technology. For many years, DYNAFORM has been used by tooling engineers as a virtual tryout for metal stamping. Engineers can go beyond identifying problem areas by incorporating design optimization to improve performance and quality - reducing wrinkling, thinning and tearing. In the simulations shown above, the evidence of cracking is greatly reduced (red areas). The incorporation of optimization streamlines die design, improves product performance and reduces manufacturing time and cost by first specifying constraints and then allowing simulation iterations to search for the best possible solution. As a result, higher performing, higher quality products can be can be developed, while greater manufacturing efficiency is achieved. Using design optimization, a firm can reduce costs by identifying the optimal variables for sheet metal stamping. Production constraints can be entered as guidelines and SHERPA finds the ideal values for the specified variables. Namely, OP uses this process to optimize drawbead rates. The system identifies the optimal values and updates the database automatically. *SHERPA is a trademark of Red Cedar Technology