Altair HyperForm. Incremental Stamping Analysis

Altair HyperForm Incremental Stamping Analysis

Altair Engineering Contact Information Web site FTP site www.altair.com Address: ftp.altair.com or ftp2.altair.com or http://ftp.altair.com/ftp Login: ftp Password: <your e-mail address> Location Telephone e-mail North America 248.614.2425 HyperWorks hwsupport@altair.com HyperMesh hmsupport@altair.com HyperForm OptiStruct MotionView HyperView HyperGraph HyperStudy HyperOpt Process Manager China 86.21.5393.0011 support@altair.com.cn France 33.1.4133.0990 francesupport@altair.com Germany 49.7031.6208.22 hwsupport@altair.de India 91.80.26588540 1600.44.0234 (toll free) support@india.altair.com Italy 39.800.905.595 support@altairtorino.it Japan 81.3.5396.1341 81.3.5396.2881 support@altairjp.co.jp Korea 82.31.728.8600 support@altair.co.kr Scandinavia 46.46.286.2052 support@altair.se United Kingdom 44.2476.323.600 support@uk.altair.com hfsupport@altair.com ossupport@altair.com mvsupport@altair.com hvsupport@altair.com hgsupport@altair.com hstsupport@altair.com hosupport@altair.com pmgrsupport@altair.com The following countries have distributors for Altair Engineering: Australia, Brazil, Czech Republic, Greece, New Zealand, Romania, South Korea, Singapore, Spain, and Taiwan. See www.altair.com for complete contact information. 2005 Altair Engineering, Inc. All rights reserved. Trademark and Registered Trademark Acknowledgments HyperForm, HyperGraph, HyperMesh, HyperOpt, HyperShape, HyperStudy, HyperView, HyperView Player, HyperWeb, HyperWorks, MotionView, MotionSolve, Process Manager, BatchMesher and OptiStruct are registered trademarks of Altair Engineering, Inc. All other trademarks and registered trademarks are the property of their respective owners. HF70_Incr_ReleaseA.doc, created on January 21, 2005

Table of Contents Chapter 1: Draw Forming Exercise...9 Model Building...10 Section Definition...12 Material Definition...13 Component Definition...13 Tool Build...15 Symmetry Plane Constraints...16 Tool Motion...17 Binder Loads...17 Run Analysis...18 Summary...18 Chapter 2: Drawbeads Exercise...19 Create Analytical Drawbeads...20 Set Tool Motion...23 Set Tool Load...24 Summary...24 Chapter 3: Springback Exercise...25 Importing a Dynain File...26 Section Definition...27 Material Definition...27 Set up Springback Analysis...28 Summary...30 HyperForm 7.0 Incremental Stamping Analysis i

Table of Contents Chapter 4: Trimming Exercise... 31 Importing a Dynain File...32 Section Definition...32 Material Definition...33 Importing an.iges File...33 Setting up a Trimming Operation...34 Summary...35 Chapter 5: Gravity Exercise... 37 Section Definition...38 Material Definition...38 Autopositioning...39 Contact Definitions...40 Set up Run...40 Summary...41 Chapter 6: Binderwrap and Forming... 43 Import Files...44 Define Sections...44 Define Materials...45 Tool Build...46 Define Tool...48 Birth and Death Time Concepts...49 Summary...49 Chapter 7: Redraw Exercise... 51 Importing Files...52 Section Definition...52 Material Definition...53 Autopositioning...54 Tool Motion...54 Tool Loads...55 Analysis...56 Summary...56 ii Incremental Stamping Analysis HyperForm 7.0

Table of Contents Appendix A: Introduction to Macros...57 Overview...57 What is a HyperForm Macro...58 The Macro Menu...58 Files Associated with HyperForm Macros...59 HyperForm Options Panel...59 HyperForm Macro Commands...60 HyperForm Macro Creation Process...61 Summary...66 Appendix B: Transferring HyperForm 1Step Results to LS-DYNA...67 Procedures for Preparing a Dynain File for use in a Crash Simulation...67 Important Files...70 HyperForm 7.0 Incremental Stamping Analysis iii

Table of Contents iv Incremental Stamping Analysis HyperForm 7.0

Preface HyperForm is a finite element based sheet metal forming simulation software. It combines a one-step solver and incremental forming solution with the geometry manipulation and mesh generation capabilities of Altair HyperMesh. Used in a traditional classroom setting, this course manual will help you become familiar with using various HyperForm panels and utilities for defining models for incremental stamping analysis. It also introduces post-processing of results using Altair HyperView. Before working through this course manual, it is suggested you complete the course manual named Altair HyperForm, 1-Step Stamping Analysis as it introduces HyperForm's graphical user interface, and geometry data clean-up and meshing functionality. HyperForm 7.0 Incremental Stamping Analysis 1

Preface Who should attend This course is designed to directly benefit engineering analysts, stamping product designers, and engineering and product managers associated with the sheet metal forming industry. Manual notations This manual uses the following notations: courier for text that you type in. bold italic for panel names, button names, and sub-panel names. Information that is of importance or warning messages will appear in a note box.. This is an example of a note box. Important information appears here.! This is an example of a warning box. Important information appears here. For more help Should you want additional help with material in this course, see the back of the title page of this manual for contact information. Comments about this manual may be directed to documentation@altair.com. 2 Incremental Stamping Analysis HyperForm 7.0

Introduction to Incremental The HyperForm Incremental (Incr) interface provides a customized interface to set up incremental metal forming analysis using LS-DYNA. The Incremental interface allows you to accurately model forming processes. Instead of modeling just the final part shape, as in 1Step analysis, the Incremental interface uses a more rigorous modeling approach. As the name implies, small solution steps or increments are taken to solve the problem. In this way, the incremental method allows you to accurately model important metal forming processes (such as binderwrap, single or multi-stage forming, trimming, and springback). Solving a problem incrementally allows you to detect the stage at which the process defects (wrinkles, thinning or tears) occur in the blank. You can then take corrective action to eliminate these defects by modifying the process in various ways (changing tool loads, tool motion, or tool shape, for example). The Incremental method allows you to represent all tool surfaces, prescribe the tool motions, apply tool loads, define material properties of the blank, and model the contact interaction between the tools and the blank. This section introduces the HyperForm Incremental Interface using process-specific examples to illustrate the ease with which it is possible to set up an incremental metalforming analysis. HyperForm 7.0 Incremental Stamping Analysis 3

Introduction The interface The incr panel supports incremental metal forming analysis using the LS-DYNA solver. Its panels help set-up the following input conditions for an incremental analysis with LS- DYNA in a highly automated fashion. You can define: input parameters, such as material properties for a deforming blank. the relative position and contact condition of the stamping tools. process conditions such as tool kinematics, drawbeads. and blankholder tonnage. Figure Introduction 1.1: Incr panel 4 Incremental Stamping Analysis HyperForm 7.0

Introduction The panels A brief description of the function of the main panels found on this page follows. Sections Allows you to create section properties for a component and define the corresponding thickness. Materials Allows you to create the material properties for a rigid tool or a deformable blank. A hardening curve corresponding to the stress-strain behavior of the deformable blank can also be created based on a power law or as a set of points from an external file. Components Allows you to create a component and prescribe the corresponding elements, section and material properties. A toggle switch enables adaptive meshing for a deforming blank if required. Loadcols Allows you to create a load collector that may hold applied velocities, forces or constraint conditions. Curves Allows you to create a curve by inputting the data in the available fields or by reading an external file. Also, any curve inside the current model can be reviewed or modified using the function named internal. Tool Build Consists of several tool creation and positioning options. Typically, you will be starting with a mesh for the blank and the face of the die. The auto build/setup function automatically creates additional tools by offsetting, creates material definitions, creates contact definitions and autopositions the tools. The tool offset function creates a new mesh component by offsetting elements of another. The autoposition function positions two or more components until they are just in contact. HyperForm 7.0 Incremental Stamping Analysis 5

Introduction Tool Motion Allows you to prescribe the motion of the tools. It automatically calculates the velocity curve and termination time for a moving tool based on its expected travel and maximum velocity. The history function automatically calculates a time step for a stable and accurate solution and also allows you to prescribe the intervals at which the results are output. Tool Loads Allows you to prescribe a force to a specified rigid tool. It allows you to choose rigid body stoppers to limit the displacement and velocity in order to minimize the inertial effects for the rigid tool under a specified force. Drawbeads Allows you to set up analytical drawbeads that create restraining condition during stamping. The inputs for the drawbead forces can either be numbers corresponding to the restraining and closure force or you can just prescribe it as a percent of the locking force. The calculate function computes analytically, the restraining, closure and locking force as well as the geometry that causes locking based on a prescribed drawbead geometry, material properties and friction conditions for the deforming blank. Contacts Allows you to set up contact condition between a single pair of components or multiple sets of components. Penetration Allows you to check components for contact surface penetrations. It also allows you to determine how much penetration is occurring and move the penetrating nodes in order to eliminate the penetration. Advanced Conveniently allows you to set up advanced forming processes such as gravity, springback, trimming, coarsening, and mapping. Run Analysis Allows you to automatically create the input file and interactively submit the job for an LS-DYNA analysis. A summary sheet can be invoked which will show a brief overview of the input data. A preview animation of the tool motion is possible from this panel. An option to write out a dynain file with the mesh and adaptivity data as well as thickness, stresses and plastic strain can be toggled from this panel. 6 Incremental Stamping Analysis HyperForm 7.0

Introduction Load Result Allows you to automatically invoke HyperView for visualizing the results corresponding to the current model. HyperView is a high performance visualization tool with a multitude of features to help review metal forming analysis results. Process Macros All the incremental macros are located on the Incr page of the macro area (top-right-hand side of the HyperForm window). The incremental process macros allow the user to more easily setup different application types. Each application type is organized under its application group's heading. The different application types that are available for setup using the macros include: Form 1st forming operation setup Multi 2nd or nth forming operation setup Trim Trimming operation setup Coarse Coarsening of blank mesh setup Sprbk Springback setup Grav Gravity setup The setup process will change according to the application type chosen. For instance, the setup for Form application type is shown in Figure 1.2. The sequence of tasks starts from the top and guides you through each step included in the specific application type. Further explanation of each application type will be provided in the subsequent exercises. Exercises Seven separate exercises illustrate application-specific problems using one or more of the Incr panels. The exercises are: Draw Forming, Drawbeads, Springback, Trimming, Gravity, Binderwrap & Forming, and Redraw. HyperForm 7.0 Incremental Stamping Analysis 7

Introduction 8 Incremental Stamping Analysis HyperForm 7.0

Chapter 1 Draw Forming Exercise Figure 1.1: The model This exercise illustrates the basic draw forming setup procedure. The example uses a simple box forming process. All tool components are generated from the base die tool mesh. Appropriate material and section properties are assigned to each component. Tool kinematics, loading conditions, and symmetric boundary conditions are also applied. Summary of Topics covered Import die geometry Meshing the die geometry with R-Mesh Import of blank geometry Meshing blank geometry Section definition Material definition Tool Build Tool Motion Tool Loads HyperForm 7.0 Incremental Stamping Analysis 9

Chapter 1: Draw Forming Model Building Step 1: Import the die geometry 1. From the macro menu, under Incr: Model, click CAD. 2. Click import and browse the directories to find the file: Die_geom_rev1.iges. 3. Click open. 4. Click return. Step 2: Rename the die component and change color 1. From the macro menu, under Incr, click rename. 2. Verify that the triangular selector is set to comps. 3. Click original name = and select lvl1. 4. Click new name = and type Die. 5. Click return. 6. Under Incr, click color. 7. Click comps and select Die. 8. Click color and select Color 8. 9. Click set color. 10. Click return. 10 Incremental Stamping Analysis HyperForm 7.0

Chapter 1: Draw Forming Step 3: Mesh die using R-Mesh 1. From the macro menu, under Incr: Model, click R-Mesh. The Rigid Tool Surface Meshing window appears (shown below). 2. Keep the default values and click Mesh. 3. Click surfs, select by collector, and select Die. 4. Click proceed. Step 4: Import blank geometry 1. From the macro menu, under Incr: Model, click CAD. 2. Click import and browse the directories to find the file: Blank_geom.igs. 3. Click open. 4. Click return. Step 5: Rename the blank component and change color 1. From the Incr page, click rename. 2. Verify that the selector is set to comps. 3. Click original name = and select lvl2. 4. Click new name = and type Blank. 5. Click return. 6. From the Incr page, click color. 7. Click comps and select Blank. 8. Click color and select Color 11. 9. Click set color and click return. HyperForm 7.0 Incremental Stamping Analysis 11

Chapter 1: Draw Forming Step 6: Mesh the blank component 1. From the permanent menu, click global. 2. Click component= and select Blank. 3. Click element size= and enter 20.00. 4. Click return. 5. From the macro menu, under Incr: Model, click Mesh. 6. Click surfs, select by collector, and select Blank. 7. Verify that the element size is 20.00. 8. Check the reset meshing parameters to: box. 9. Click the selector button next to mixed and select quads. 10. Click mesh to invoke the meshing module. 11. Click mesh again and click return to accept the mesh. 12. Click return again to exit the automesh panel. 13. From the macro menu, under Disp, click Off (beside Geom:). This turns off all geometry, as we will be working with mesh from this point on. Section Definition Step 1: Create blank section properties 1. From the macro menu under Incr, choose Form, then Sections. 2. Click section = and enter blank_section. 3. Click thickness = and enter 1.0. (mm). 4. Click create. 5. Click return. 12 Incremental Stamping Analysis HyperForm 7.0

Chapter 1: Draw Forming Material Definition Step 1: Create blank material properties 1. From the macro menu under Incr, choose Form, then click Materials. 2. Click materials = and enter CRDQ_steel. 3. Click card image = and select TransAnisoElasticPlastic. 4. Click import curve. 5. Click curve: and enter stress_strain_curve. 6. Click sigy = and enter 185. (MPa). 7. Click k = and enter 550. (MPa). 8. Click n = and enter 0.21. 9. Click create. 10. Click back. 11. Click create. 12. Click return. Component Definition Step 1: Assign section and material properties for the blank component 1. From the macro menu under Incr, choose Form, and click Comps. 2. Double-click component: and select Blank. 3. Click section: and select blank_section. 4. Click materials: and select CRDQ_steel. 5. Click the adaptive checkbox on. 6. Click update. 7. Click return. By default, three levels of adaptivity are enabled. Since the starting element size in the blank is approximately 16 mm, the smallest element after maximum refinement will be approximately 4 mm. Change the adaptive levels by using the control card panel, and editing the Adaptive card. The parameter to edit is MAXLVL. Please see the LS-DYNA manual for more detailed information. HyperForm 7.0 Incremental Stamping Analysis 13

Chapter 1: Draw Forming Step 2: Update die as a tool type component using table summary macro 1. From the macro menu under Incr, choose Form, and click List. A table summarizing each component definition is displayed as shown in Figure 1.2. Figure 1.2: Summary table List summary macro: This macro generates a list of all components defined in the HyperForm model. For a HyperForm Incremental setup, each component can have a blank or tool type definition. A blank type definition indicates that the component has an assigned section thickness and deformable type material property (eg. transversely anisotropic material elastic plastic, piecewise linear plastic, etc). A tool type definition indicates that the component has an assigned section thickness and rigid material property (Note that the thickness defined in the section property is not used in the contact definition). For components that are intended to become tool type components, the macro will automatically create and assign the necessary section and rigid material properties. 2. For the die component, click the free button under TYPE and select tool. Notice that a material name, die_mat, is created with fully fixed degree of freedom constraints. The buttons below the headings TRANS and ROT are both set to fixed to indicate this fully constrained condition. To modify these translational and rotational degrees of freedom, you can click the corresponding fixed button to select from a list of possible constraint options. For example, a tool is defined with fully fixed constraints and it is desired to allow only translation in the z-direction. To set this up, the approach would be to select the z setting under the TRANS heading, and then ensure that, under the ROT heading, the fixed setting was chosen. 3. Click cancel. For this tutorial, please ensure the die tool component is setup with a fully fixed constraint. 14 Incremental Stamping Analysis HyperForm 7.0

Chapter 1: Draw Forming Step 3: Display only the die component 1. From the permanent menu, select disp. 2. Click none. 3. Select die component. 4. Click return. Tool Build Step 1: Build tool components 1. From the macro menu under Incr, choose Form, then click Tool Build (under Setup). 2. Click punch source: elems and select on plane. 3. Pick three corners of the binder for N1, N2, and N3. 4. Click select entities. 5. Click punch source: elems and select save. 6. Click punch source: elems and select reverse. 7. Click binder source: elems and select retrieve. 8. From the permanent menu, select disp. 9. Select the Blank component. 10. Click return. 11. Click blank: comps and select the Blank component. Notice that after selecting the blank component, the thickness value field t is updated with the corresponding thickness (1.0 mm). The punch offset amount is set using this thickness value. The punch offset is calculated to be thickness plus 20%. So for this case it is 1.2*1.0 mm = 1.2 mm. If required, the punch offset can be modified from the calculated value. 12. Click create. 13. Click return. HyperForm 7.0 Incremental Stamping Analysis 15

Chapter 1: Draw Forming Step 2: Set a top view of the blank 1. From the permanent menu, select view. 2. Click top. 3. From the permanent menu, select disp. 4. Click none. 5. Select blank component. 6. Click return. Symmetry Plane Constraints Step 1: Define symmetry plane constraints 1. From the macro menu under Incr, select Form and then click Symmetry Plane. 2. Select the Symmetry Plane YZ. 3. Click create. 4. Pick a node on the symmetric plane of the blank (right-hand edge). 5. Click proceed. Step 2: Set an iso view of the all components 1. From the permanent menu, select view. 2. Click iso 1. 3. From the permanent menu, select disp. 4. Click all. 5. Click return. 16 Incremental Stamping Analysis HyperForm 7.0

Chapter 1: Draw Forming Tool Motion Step 1: Define tool motion 1. From the macro menu under Incr, select Form, and then click Tool Motion. 2. Click moving tool and select punch component. 3. Click maximum velocity and enter 5000. (mm/s) Notice that total travel is automatically set. This value is automatically calculated because the punch was generated using the auto build/setup panel. 4. Click set up. 5. Click the history sub-panel. 6. Click cycles/travel and enter 100. (cycles / mm of tool travel) 7. Click update. 8. Click return. Binder Loads Step 1: Define binder load 1. From the macro menu under Incr, select Form and then click Tool Load. 2. Click tool = and select Binder. 3. Click tool force and enter -100000. (N) 4. Click max velocity and enter 500. (mm/s) 5. Click setup. 6. Click return. A force of 100kN is applied to the binder. A rigid body stopper limits the maximum velocity of the binder in order to minimize inertial effects. HyperForm 7.0 Incremental Stamping Analysis 17

Chapter 1: Draw Forming Run Analysis Step 1: Save analysis 1. From the macro menu under Incr, select Form and click Save (under Setup). 2. Click save as and save the file as forming1.hf60. 3. Click save. 4. Click return. Step 2: Run analysis 1. From the macro menu under Incr, select Form and click Run. 2. Make sure that the path to the LS-DYNA executable has been set. To do this, edit the hf.cfg file in the <install directory>\hf\bin directory. 3. Click create dynain. 4. Click applied comps: comps and select Blank. 5. Click setup. At the end of the computation, LS-DYNA writes out a file called dynain. This file contains all of the stress and strain information necessary to perform subsequent operations. This file can be read directly by HyperForm and is essential for performing multi-stage setups. 6. Click return. 7. Click run. Step 3: Save analysis 1. From the macro menu under Incr, select Form and click Save (under Setup). 2. Click save. 3. Click yes to overwrite. 4. Click return. Summary This exercise described a procedure that allows you to easily manage the setup of a basic draw forming operation. The procedure focused on section definition, material definition, tool build, tool motion, and tool loads. 18 Incremental Stamping Analysis HyperForm 7.0

Chapter 2 Drawbeads Exercise Figure 2.1: Simple box model This exercise illustrates how to use analytical drawbeads. For this example, a simple box forming process is used. Drawbeads are added to an existing draw forming setup (see Forming Exercise). Summary of Topics covered Create analytical drawbeads Tool Motion Birth and death time concepts Tool Loads HyperForm 7.0 Incremental Stamping Analysis 19

Chapter 2: Drawbeads Step 1: Load HyperForm setup file 1. From the macro menu, under Incr: Model, click HF. 2. Click file = and browse the directories to find the file: drawbeads.hf60. 3. Click retrieve. 4. Click return. Step 2: Translate binder 1. From the Mesh page, select the translate panel. 2. Set the selector to comps and select the Binder component. 3. Set the direction switch to z-axis. 4. Set the toggle to magnitude = and enter 6.0. (mm) 5. Click translate +. 6. Click return. Translate the binder in the z-direction to account for the addition of an analytical drawbead of height 6.0 mm. Step 3: Import drawbead IGES line 1. From the macro menu, under Incr: Model, click CAD. 2. Click import and browse the directories to find the file: drawbead_lines.igs. Create Analytical Drawbeads Step 1: Display only the binder component 1. From the permanent menu, select disp. 2. Click none. 3. Select die and lvl4 component 4. Click return. 20 Incremental Stamping Analysis HyperForm 7.0

Chapter 2: Drawbeads Step 2: Create analytical drawbeads 1. From the macro menu, under Incr, select Form, and click Drawbeads. 2. Click the field beside drawbead: and enter the name db1. 3. Click comps and select the blank component as the master. 4. Click line and select the line for db1 as shown in the figure 2.2. Figure 2.2: Lines to select 5. Click attached to and select component binder. 6. Click calculate to switch to the drawbead force calculator. 7. Click shoulder radius and enter 2.0. (mm). 8. Click calculate. 9. Click back to accept calculated values. 10. Click color and select color 5. 11. Click create to generate drawbead. HyperForm 7.0 Incremental Stamping Analysis 21

Chapter 2: Drawbeads Step 3: Create additional drawbeads 1. Click the field beside drawbead = and enter the name db2. 2. Click comps and select the blank component as the master. 3. Click line and select the line for db2 as shown in Figure 2.2. 4. Click color and select color 9. 5. Click create. 6. Click the field beside drawbead = and enter the name db3. 7. Click comps and select the blank component as the master. 8. Click line and select the line for db3 as shown in Figure 2.2. 9. Click color and select color 13. 10. Click create. Step 4: Set an iso view of all components 1. From the permanent menu, select view. 2. Click iso1. 3. From the permanent menu, select disp. 4. Click all. 5. Click return. 22 Incremental Stamping Analysis HyperForm 7.0

Chapter 2: Drawbeads Set Tool Motion Step 1: Define binder tool motion 1. From the macro menu under Incr, select Form, and click Tool Motion. 2. Click moving tool and select the Binder component. 3. Click maximum velocity and enter 2000. (mm/s) 4. Click total travel and enter 6.0. (mm) 5. Check mark ON the termination time setup option. 6. Click set up. 7. Click history sub-panel. Note that the calculated termination time is T= 0.005 seconds. This time will be used again later in the exercise. 8. Click motion sub-panel. 9. Click edit. 10. Click the DEATH field and enter 0.005. (s) 11. Click return. This death time will ensure that the prescribed motion of the binder is stopped before a force load is applied. Step 2: Define punch tool motion 1. Click moving tool and select Punch component. 2. Click starting time and enter 0.005. (s) This start time offset ensures the punch does not start moving until the binder is fully closed. 3. Checkmark ON the termination time setup option. 4. Click update. 5. Click the history sub-panel. Note that the termination time, T, is now calculated to be 2.090e-2 seconds. 6. Click cycles/travel and enter 100. 7. Click update. 8. Click return. HyperForm 7.0 Incremental Stamping Analysis 23

Chapter 2: Drawbeads Set Tool Load Step 1: Define binder load 1. From the macro menu under Incr, select Form, and then click Save. 2. Click tool = and select Binder. 3. Click edit beside the stoppers option checkbox. 4. Click TB and enter 0.005. (s) 5. Click return. This ensures the rigid body stopper becomes active as soon as the prescribed motion of the binder is killed. 6. Click update. 7. Click return. Step 2: Save analysis 1. From the macro menu under Incr, select Form, and then click Save. 2. Click save as and save the file as drawbeads1.hf60. 3. Click save. 4. Click return. Step 3: Run analysis 1. From the macro menu under Incr, select Form, and then click Run. Make sure that the path to the LS-DYNA executable is set. To do this, edit the hf.cfg file in the altair\hf\bin directory. 2. Click return. 3. Click run. Summary This exercise described a procedure allowing you to more easily manage the setup of drawbeads in a basic draw forming operation. The procedure focused on defining analytical drawbeads, tool motion, tool loads, and birth and death time concepts. 24 Incremental Stamping Analysis HyperForm 7.0

Chapter 3 Springback Exercise Figure 3.1: Model for springback analysis This exercise illustrates the setup procedure for performing a springback analysis. The part shape, stress and strain state at the end of a simple draw forming operation are the inputs to this analysis (see Forming Exercise). Appropriate material and section properties are assigned to the blank component. Fixture constraints are applied to the part to eliminate rigid body modes. Summary of Topics covered: Importing a dynain file Section definition Material definition Setting up a springback analysis HyperForm 7.0 Incremental Stamping Analysis 25

Chapter 3: Springback Importing a Dynain File Step 1: Import dynain file 1. From the macro menu under Incr, choose Sprbk and then click Import Dynain. 2. Click import and browse the directories to find the file: forming_dynain. 3. Click open. 4. Click yes. 5. Click return. During import of the dynain file, only the node and element definitions are. read into HyperForm. The adaptive constraints, initial stress and initial strain quantities are automatically placed into a new file called dynain.hmx. This extra information is automatically included in the new setup by use of the *INCLUDE card.! No renumbering or rotations of the imported dynain component is allowed. The stress and strain tensors are written with respect to a global coordinate system and require a suitable transformation. Currently, HyperForm does not support transforming these stress and strain tensors. Step 2: Rename dynain component 1. From the macro menu under Incr, choose Sprbk, and click Rename. 2. Click collector = and select comps 1. 3. Click new name = and enter blank. 4. Click rename. 5. Click return. 26 Incremental Stamping Analysis HyperForm 7.0

Chapter 3: Springback Section Definition Step 1: Create blank section properties 1. From the macro menu under Incr, choose Sprbk, and click Sections. 2. Click section = and enter blank_section. 3. Click thickness = and enter 1.0. (mm) 4. Click create. 5. Click return. Material Definition Step 1: Create blank material properties 1. From the macro menu under Incr, choose Sprbk, and click Materials. 2. Click materials = and enter CRDQ_steel. 3. Click card image = and select TransAnisoElasticPlastic. 4. Click import curve. 5. Click curve: and enter stress_strain_curve. 6. Click sigy = and enter 185. (MPa) 7. Click k = and enter 550. (MPa) 8. Click n = and enter 0.21. 9. Click create. 10. Click back. 11. Click create. 12. Click return. Blank material properties are defined using a transversely anisotropic elastic plastic material model. Material density, Poisson s ratio, and Young s modulus are assumed to be that of steel. A Holloman-type stress strain curve is created and assigned to the material. Alternatively, an elastic material model could be used to model the blank since the stress recover during spring-back is essentially elastic. HyperForm 7.0 Incremental Stamping Analysis 27

Chapter 3: Springback Set up Springback Analysis Step 1: Assign section and material properties to the blank component 1. From the macro menu under Incr, choose Sprbk, and click Components. 2. Click component: and select blank. 3. Click section: and select blank_section. 4. Click materials: and select CRDQ_steel. 5. Click update. 6. Click return. Step 2: Set a top view of the blank 1. From the permanent menu, select view. 2. Click top. 28 Incremental Stamping Analysis HyperForm 7.0

Chapter 3: Springback Step 3: Setup spring-back analysis 1. From the macro menu under Incr, choose Sprbk, and click Sprbk Setup. 2. Make sure that the option using dynain is set. 3. Click constraints: nodes and select node A as shown in the figure below. 4. Click setup. 5. From the permanent menu, click p. 6. Click constraints: nodes and select node B as shown in the figure below. 7. Click dof1 and dof2 to uncheck OFF. 8. Click update. 9. From the permanent menu, click p. 10. Click return. Constraint nodes are chosen to eliminate rigid body modes. Artificial stabilization is used to gradually unload stress in the part. Figure 3.2: Constraint nodes Step 4: Save analysis 1. From the macro menu under Incr, choose Grav, and then click Save (under Setup). 2. Click save as and use the file browser to save the file as springback1.hf60. 3. Click save. 4. Click return. HyperForm 7.0 Incremental Stamping Analysis 29

Chapter 3: Springback Step 5: Run analysis 1. From the macro menu under Incr, choose Sprbk, and click Run. 2. Make sure that the path to the LS-DYNA executable is set. To do this, edit the hf.cfg file in the altair\hf\bin directory. 3. Click return. 4. Click run. Summary This exercise describes a procedure allowing you to more easily manage the setup of a springback analysis. The procedure focuses on importing a dynain file, section definition, material definition, and springback setup. 30 Incremental Stamping Analysis HyperForm 7.0

Chapter 4 Trimming Exercise Figure 4.1: Model for trimming This exercise illustrates the setup procedure for performing a trimming operation. This example uses a simple box form. The part shape, stress and strain state at the end of a simple draw forming operation are the inputs for this analysis (see Forming Exercise). Appropriate material and section properties are assigned to the blank component. A trim line is imported from a file and the trimming operation is setup. Summary of Topics covered Importing a dynain file Section definition Material definition Importing an IGES curve file Setting up a trimming operation HyperForm 7.0 Incremental Stamping Analysis 31

Chapter 4: Trimming Importing a Dynain File Step 1: Import dynain file 1. From the macro menu under Incr, choose Trim, and then click Import Dynain. 2. Click import and browse the directories to find the file: forming_dynain. 3. Click yes. 4. Click return..! During import of the dynain file, only the node and element definitions are read into HyperForm. The adaptive constraints, initial stress and initial strain quantities are automatically placed into a new file called dynain.hmx. This extra information is automatically included in the new setup by use of the *INCLUDE card. No renumbering or rotations of the imported dynain component is allowed. The stress and strain tensors are written with respect to a global coordinate system and require a suitable transformation. Currently, HyperForm does not support transforming these stress and strain tensors. Step 2: Rename dynain component 1. From the macro menu under Incr, choose Trim, and click Rename. 2. Click collector = and select comps 1. 3. Click new name = and enter blank. 4. Click rename. 5. Click return. Section Definition Step 1: Create blank section properties 1. From the macro menu under Incr, choose Trim, and click Sections. 2. Click section = and enter blank_section. 3. Click thickness = and enter 1.0. (mm) 4. Click create and return. 32 Incremental Stamping Analysis HyperForm 7.0

Chapter 4: Trimming Material Definition Step 1: Create blank material properties 1. From the macro menu under Incr, choose Trim, and click Materials. 2. Click materials = and enter CRDQ_steel. 3. Click card image = and select TransAnisoElasticPlastic. 4. Click import curve. 5. Click curve = and enter stress_strain_curve. 6. Click sigy = and enter 185. (MPa) 7. Click k = and enter 550. (MPa) 8. Click n = and enter 0.21. 9. Click create. 10. Click back. 11. Click create. 12. Click return. Step 2: Assign section and material properties to the blank component 1. From the macro menu under Incr, choose Trim, and click Components. 2. Click component: and select blank. 3. Click section: and select blank_section. 4. Click materials: and select CRDQ_steel. 5. Click update. 6. Click return. Importing an.iges File Step 1: Import iges file 1. From the macro menu under Incr, choose Trim, and click Import line. 2. Click filename = and browse the directories to select: trim_line.igs. 3. Click import. 4. Click return. HyperForm 7.0 Incremental Stamping Analysis 33

Chapter 4: Trimming Setting up a Trimming Operation Step 1: Modify color of trim curve 1. From the Incr page, select the color panel. 2. Click comps and select lvl1. 3. Click color and select Color 12. 4. Click set color. 5. Click return. Step 2: Combine trim curve lines 1. From the macro menu under Incr, choose Trim, and click Combine Line. 2. Click lines in the order shown in the Figure 4.2. Two selected lines will be combined into a new line. Repeat the selection process using the new line and the next adjacent line until all lines have been combined into a single line. Figure 4.2: Lines to combine 34 Incremental Stamping Analysis HyperForm 7.0

Chapter 4: Trimming Step 3: Setup a trimming operation 1. From the macro menu under Incr, choose Trim, and click Trimming Setup. 2. Click trim comps: comps and select blank component. 3. Click trim lines: lines and select displayed. 4. Click direction selector and select z-axis. 5. Click trim option toggle and switch to remove element inside. 6. Click setup. 7. Click return. Step 4: Save analysis 1. From the macro menu under Incr, choose Trim, and click Save. 2. Click save as and use the file browser to save the file as: trimming1.hf60. 3. Click save. 4. Click return. Step 5: Run analysis 1. From the macro menu under Incr, choose Trim, and click Run. 2. Make sure that the path to the LS-DYNA executable is set. To do this, edit the hf.cfg file in the <install directory>\hf\bin directory. 3. Click create dynain. 4. Click applied comps: comps and select blank. 5. Click setup. At the end of the computation, LS-DYNA will write out a file called dynain. This file contains all the stress and strain information necessary to perform additional operations. This file can be read directly by HyperForm and is essential for performing multi-stage setups. 6. Click return. 7. Click run. Summary This exercise describes a procedure allowing you to more easily manage the setup of a trimming operation. The procedure focused on importing a dynain file, section definition, importing an IGES curve, and trimming setup. HyperForm 7.0 Incremental Stamping Analysis 35

Chapter 4: Trimming 36 Incremental Stamping Analysis HyperForm 7.0

Chapter 5 Gravity Exercise Figure 5.1: Model for gravity exercise This exercise illustrates the set up procedure for performing a gravity analysis. A setup file containing the blank and die mesh provides the starting point. The appropriate material and section properties are assigned to the tool and blank. The components are then correctly positioned and the contacts defined. Finally, a gravity setup, using dynamic relaxation is enabled. Summary of Topics covered Section definition Material definition Autopositioning Contact definition Set up of a gravity analysis HyperForm 7.0 Incremental Stamping Analysis 37

Chapter 5: Gravity Step 1: Load HyperForm setup file 1. From the macro menu, under Model, click HF. 2. Click retrieve and browse the directories to find the file gravity.hf60. 3. Click open. 4. Click return. Section Definition Step 1: Create blank section properties 1. From the macro menu under Inc, choose Grav, and click Sections. 2. Click section = and enter blank_section. 3. Click thickness = and enter 0.5. (mm) 4. Click create. 5. Click return. Material Definition Step 1: Create blank material properties 1. From the macro menu under Incr, choose Grav, and click Materials. 2. Click materials = and enter CRDQ_steel. 3. Click card image = and select TransAnisoElasticPlastic. 4. Click import curve. 5. Click curve = and enter stress_strain_curve. 6. Click sigy = and enter 185. (MPa) 7. Click k = and enter 550. (MPa) 8. Click n = and enter 0.21. 9. Click create. 10. Click back. 11. Click create. 12. Click return. 38 Incremental Stamping Analysis HyperForm 7.0

Chapter 5: Gravity Step 2: Update binder as a tool type component using table summary macro 1. From the macro menu under Incr, choose Form, and click List. 2. For the binder component, click the free button under TYPE and select tool. 3. Click update. 4. Click cancel. Step 3: Assign section and material properties for the blank component 1. From the macro menu under Incr, choose Grav, and click Comps. 2. Click component = and select blank. 3. Click section = and select blank_section. 4. Click materials = and select CRDQ_steel. 5. Click update. 6. Click return. Autopositioning Step 1: Autoposition blank onto binder surface 1. From the macro menu under Incr, choose Grav, and click Autoposition. 2. Select the two parts sub-panel. 3. Click translation part: comps and select blank component. 4. Click reference part: comps and select binder component. 5. Click adjust. 6. Click return. HyperForm 7.0 Incremental Stamping Analysis 39

Chapter 5: Gravity Contact Definitions Step 1: Create contact definitions of die to blank surface 1. From the macro menu under Incr, choose Grav, and click Contacts. 2. Select the multiple sub-panel. 3. Click master: comps and select Die. 4. Click slave: comps and select blank. 5. Click create. 6. Click return. Set up Run Step 1: Set up gravity run 1. From the macro menu under Incr, choose Grav, and click Gravity Setup. 2. Click applied comps: comps and select blank component. 3. Select the implicit option. The primary purpose of simulating gravity is to compute the shape of the deformed sheet due to a gravity load. This can help to reduce the simulated tool travel distance, and eliminates some of the low frequency dynamic oscillation that occurs when the tools first contact the blank. Tow methods are available for set up: 1) dynamic implicit gravity, and 2) explicit dynamic relaxation. The explicit dynamic relaxation method is reliable; however, solution times tend to be longer. They dynamic implicit method uses the implicit solver to obtain quick solution times. 4. Click setup. 5. Click return. Step 2: Save analysis 1. From the macro menu under Incr, choose Grav, and click Save. 2. Click save as and save the file as: gravity1.hf5. 3. Click save. 4. Click return. 40 Incremental Stamping Analysis HyperForm 7.0

Chapter 5: Gravity Step 3: Run analysis 1. From the macro menu under Incr, choose Grav, and click Run. 2. Make sure the path to the LS-DYNA executable is set. To do this, edit the hf.cfg file in the altair\hf\bin directory. 3. Click create dynain. 4. Click applied comps: comps and select blank. 5. Click setup. 6. Click return. 7. Click run. Summary This exercise described a procedure allowing you to more easily manage the setup of a gravity analysis. The procedure focused on a section definition, material definition, tool build, too motion, tool loads, and a birth and death time concepts. HyperForm 7.0 Incremental Stamping Analysis 41

Chapter 5: Gravity 42 Incremental Stamping Analysis HyperForm 7.0

Chapter 6 Binderwrap and Forming Figure 6.1: Model for binderwrap This exercise illustrates a combined binderwrap and draw forming setup procedure. A setup file containing the die mesh provides the starting point. The blank shape at the end of the gravity analysis (see Gravity Exercise) is used in this analysis. All tool components are generated from the die tool mesh. Appropriate material and section properties are assigned to each component. Summary of Topics covered Import a dynain file Define Section Define Material Tool Build Tool Motion Tool Loads Birth and death time concepts HyperForm 7.0 Incremental Stamping Analysis 43

Chapter 6: Binderwrap and Forming Import Files Step 1: Load HyperForm setup file 1. From the macro menu under Model, click HF. 2. Click retrieve and browse the directories to find the file: bwrap_form.hf60. 3. Click open. 4. Click return. Step 2: Import dynain file 1. From the macro menu under Incr, choose Multi, and click Import Dynain. 2. Click retrieve and browse the directories to select: gravity_dynain. 3. Click yes. 4. Click return..! During import of the dynain file, only the node and element definitions are read into HyperForm. The adaptive constraints, initial stress and initial strain quantities are automatically placed into a new file called dynain.hmx. This extra information is automatically included in the new setup by use of the *INCLUDE card. No renumbering or rotations of the imported dynain component is allowed. The stress and strain tensors are written with respect to a global coordinate system and require a suitable transformation. Currently, HyperForm does not support transforming these stress and strain tensors. Define Sections Step 1: Rename dynain component 1. From the macro menu under Incr, choose Multi, and click Rename. 2. Click collector = and select comps 1. 3. Click new name = and enter blank. 4. Click rename. 5. Click return. 44 Incremental Stamping Analysis HyperForm 7.0

Chapter 6: Binderwrap and Forming Step 2: Create blank section properties 1. From the macro menu under Incr, choose Multi, and click Section. 2. Click section = and enter blank_section. 3. Click thickness = and enter 0.5. (mm) 4. Click create. 5. Click return. Define Materials Step 1: Create blank material properties 1. From the macro menu under Incr, choose Multi, and click Materials. 2. Click materials = and enter CRDQ_steel. 3. Click card image = and select TransAnisoElasticPlastic. 4. Click import curve. 5. Click curve = and enter stress_strain_curve. 6. Click sigy = and enter 185. (MPa) 7. Click k = and enter 550. (MPa) 8. Click n = and enter 0.21. 9. Click create. 10. Click back. 11. Click create. 12. Click return. Step 2: Assign section and material properties to the blank component 1. From the macro menu under Incr, choose Multi, and click Components. 2. Click component: and select blank. 3. Click section: and select blank_section. 4. Click materials: and select CRDQ_steel. 5. Click adaptive checkbox on. 6. Click update. 7. Click return. HyperForm 7.0 Incremental Stamping Analysis 45

Chapter 6: Binderwrap and Forming Step 3: Display a top view of the die component only 1. From the permanent menu, select view. 2. Click iso1. 3. From the permanent menu, select disp. 4. Click none. 5. Select die component. 6. Click return. Tool Build Step 1: Build tool components 1. From the permanent menu, select options. 2. Click feature angle and enter 2.0. (degrees) 3. Click return. Changing the feature angle to 2.0 makes selecting elements on the binder area of the die easier. 4. From the macro menu under Incr, choose Multi, and click Tool Build. 5. Select auto build/setup sub-panel. 6. Click punch source: elems and select one element on the binder area of the die as shown in Figure 6.2 below. Figure 6.2: Window that encloses elements 46 Incremental Stamping Analysis HyperForm 7.0

Chapter 6: Binderwrap and Forming 7. Click punch source: elems again, and select by face. Figure 6.3: Elements selected after a by face element selection 8. Click punch source: elems again, and select save. 9. Click punch source: elems and select reverse. 10. Click binder source: elems and select retrieve. 11. Click blank: comps and select the blank component. 12. From the permanent menu, select disp. 13. Select the blank component. 14. Click create. 15. Click return. HyperForm 7.0 Incremental Stamping Analysis 47

Chapter 6: Binderwrap and Forming Define Tool Step 1: Define tool motion 1. From the macro menu under Incr, choose Multi, and click Tool Motion. 2. Click moving tool and select Binder component. 3. Click maximum velocity and enter 2000. (mm/s) Notice total travel is automatically set (approximately 5.0 mm). This value gets calculated because the punch was generated using the auto build/setup panel. 4. Click set up. 5. Click the history sub-panel. Note the calculated termination time is T= 4.5e-3 seconds. This time will be used again later in the exercise. 6. Click the motion sub-panel. 7. Click edit. 8. Click DEATH time field and enter 4.5e-3. (s) This death time will kill the prescribed motion of the binder just before a force load is applied to it. 9. Click return. 10. Click moving tool and select Punch component. 11. Click maximum velocity and enter 5000. (mm/s) Notice the total travel is automatically set (approximately 80.7 mm). 12. Click starting time and enter 4.5e-3. (s) 13. Click termination time check ON. 14. Click set up. 15. Click the history sub-panel. 16. Click cycles/travel and enter 100. (cycles/mm of tool travel) 17. Click update. 18. Click return. 48 Incremental Stamping Analysis HyperForm 7.0

Chapter 6: Binderwrap and Forming Birth and Death Time Concepts Step 1: Define binder load 1. From the macro menu under Incr, choose Multi, and click Tool Loads. 2. Click tool = and select Binder. 3. Click tool force and enter -200000. (N) 4. Click max velocity and enter 500. (mm/s) 5. Click birth time and enter 4.5e-3. (s) 6. Click setup. A force of 200kN is applied to the binder. A rigid body stopper limits the maximum velocity of the binder in order to minimize inertial effects. This rigid body stopper is defined to be active (note birth time) only after the prescribed motion of the binder has been killed. 7. Click return. Step 2: Save analysis 1. From the macro menu under Incr, choose Form, and click Save. 2. Click save as and save the file as bwrap_form1.hf60. 3. Click save. 4. Click return. Step 3: Run analysis 1. From the macro menu under Incr, choose Form, and click Run. 2. Make sure that the path to the LS-DYNA executable is set. To do this, edit the hf.cfg file in the altair\hf\bin directory. 3. Click return. 4. Click run. Summary This exercise described a procedure allowing you to more easily manage the setup of a combined binderwrap and forming operation. The procedure focused on importing a dynain file; section definition; material definition; tool build; tool motion and tool loads; and birth and death time concepts. HyperForm 7.0 Incremental Stamping Analysis 49

Chapter 6: Binderwrap and Forming 50 Incremental Stamping Analysis HyperForm 7.0

Chapter 7 Redraw Exercise Figure 7.1: Model for second stage setup This exercise illustrates a second stage setup procedure. A setup file containing the tool meshes provides the starting point. The blank shape at the end of the binderwrap and draw forming (see Binderwrap and draw forming Exercise) is used in this analysis. Appropriate material and section properties are assigned to each component. Summary of Topics covered Importing a dynain file Section definition Material definition Multi Tool Autopositioning Tool Motion Tool Loads HyperForm 7.0 Incremental Stamping Analysis 51

Chapter 7: Redraw Importing Files Step 1: Load HyperForm setup file 1. From the macro menu under Incr, choose Model, and click HF. 2. Click retrieve and browse the directories to find the file redraw.hf60. 3. Click open. 4. Click return. Step 2: Import dynain file 1. From the macro menu under Incr, choose Multi, and click Import Dynain. 2. Click import and browse the directories to select redraw_dynain. 3. Click open. 4. Click yes. 5. Click return..! When the dynain file imports, only the node and element definitions are read into HyperForm. The adaptive constraints, initial stress and initial strain quantities are automatically placed into a new file called dynain.hmx. This extra information is automatically included in the new setup by use of the *INCLUDE card. No renumbering or rotations of the imported dynain component is allowed. The stress and strain tensors are written with respect to a global coordinate system and require a suitable transformation. Currently, HyperForm does not support transforming these stress and strain tensors. Section Definition Step 1: Rename dynain component 1. From the macro menu under Incr, choose Multi, and click Rename. 2. Click collector = and select comps 1. 3. Click new name = and enter blank. 4. Click rename. 5. Click return. 52 Incremental Stamping Analysis HyperForm 7.0

Chapter 7: Redraw Step 2: Create blank section properties 1. From the macro menu under Incr, choose Multi, and click Sections. 2. Click section = and enter blank_section. 3. Click thickness = and enter 0.5. (mm) 4. Click create. 5. Click return. Material Definition Step 1: Create blank material properties 1. From the macro menu under Incr, choose Multi, and click Materials. 2. Click materials = and enter CRDQ_steel. 3. Click card image = and select TransAnisoElasticPlastic. 4. Click import curve. 5. Click curve: and enter stress_strain_curve. 6. Click sigy = and enter 185. (MPa) 7. Click k = and enter 550. (MPa) 8. Click n = and enter 0.21. 9. Click create. 10. Click back. 11. Click create. 12. Click return. Step 2: Assign section and material properties to the blank component 1. From the macro menu under Incr, choose Multi, and click Comps. 2. Click component: and select blank. 3. Click section: and select blank_section. 4. Click materials: and select CRDQ_steel. 5. Click adaptive checkbox on. 6. Click update. 7. Click return. HyperForm 7.0 Incremental Stamping Analysis 53

Chapter 7: Redraw Autopositioning Step 1: Autoposition blank onto tools 1. From the macro menu under Incr, choose Multi, and click auto build/setup. 2. Select the autoposition sub-panel. 3. Select the multipart sub-panel. 4. Click punch: comps and select Punch component. 5. Click binder: comps and select Binder component. 6. Click die: comps and select Die component. 7. Click blank: comps and select Blank component. 8. Click create contact with blank checkbox ON. 9. Toggle moving part to die. 10. Click adjust. 11. Click return. Tool Motion Step 1: Define tool motion 1. From the macro menu under Incr, choose Multi, and click Tool Motion. 2. Click moving tool and select Die component. 3. Click maximum velocity and enter 5000. (mm/s) 4. Click total travel and enter 36.5. (mm) 5. Click set up. 6. Click the history sub-panel. 7. Click cycles/travel and enter 100. (cycles/mm of tool travel) 8. Click update. 9. Click return. 54 Incremental Stamping Analysis HyperForm 7.0

Chapter 7: Redraw Tool Loads Step 1: Define binder load 1. From the macro menu under Incr, choose Multi, and click Binder Load. 2. Click tool = and select Binder. 3. Click tool force and enter 200000. (N) 4. Click max velocity and enter 5500. (mm/s) 5. Click setup. We apply a force of 200kN to the binder. A rigid body stopper limits the maximum velocity of the binder in order to minimize inertial effects. The maximum velocity is 10% greater than the die velocity allowing the blankholder to adjust for thickening or wrinkling of the blank. 6. Click return. Step 2: Modify the Adaptivity Settings 1. From the Incr page, select the control card panel. 2. Click the Adaptive control card. 3. Click ADPSIZE and enter 11.2. (mm) 4. Click return. 5. Click return. ADPSIZE defines the minimum element size to be adapted. To maintain the adaptive levels in the blank, this parameter should be set to an element size which is slightly less than twice the size of the smallest element in your adapted blank (ADPSIZE = 1.95*smallest characteristic length). During each adaptive cycle, Dyna checks to see if any elements have a characteristic length greater than ADPSIZE, if so, then those elements can potentially adapt. Conversely, the elements smaller than ADPSIZE are not allowed to adapt. For this example, the smallest characteristic length in the blank after 3 levels is 5.76 mm so the ADPSIZE = 5.76*1.95 = 11.2 mm. HyperForm 7.0 Incremental Stamping Analysis 55

Chapter 7: Redraw Step 3: Save analysis 1. From the macro menu under Incr, choose Multi, and click Save. 2. Select the hf file sub-panel. 3. Click retrieve and save the file as redraw1.hf60. 4. Click save. 5. Click return. Analysis Step 1: Run analysis 1. From the macro menu under Incr, choose Multi, and click Run. 2. Make sure that the path to the LS-DYNA executable is set. To do this, edit the hf.cfg file in the altair\hf\bin directory. 3. Click return. 4. Click run. Summary This exercise described a procedure allowing you to more easily manage the setup of a combined binderwrap and forming operation. The procedure focused on importing a dynain file, section definition, material definition, multi-tool autopositioning, tool motion, and tool loads. 56 Incremental Stamping Analysis HyperForm 7.0

APPENDIX A Introduction to Macros This appendix contains introductory material for the use and creation of macros. For more complete information of macros and the Tcl/Tk language used to create macros, attend the Macro/Tcl/Tk training class. See our Web site, www.altair.com, for a complete list of classes and class schedules. Overview Implementation of the HyperForm macro menu began with the HyperWorks 4.0 release. You can create a customized user interface consisting of a combination of controls including buttons (which may have user-defined macros associated with them), button groups (function like radio buttons), and text. HyperForm macros allow you to combine several steps into a single mouse click. Routines you use often, such as saving the model file, or repetitive tasks that you apply to your models can be converted into macros. Ultimately, the appropriate use of macros will save time. The following material introduces the basic concepts of the HyperForm macro functionality and procedures for creating and implementing macros. The following topics are included: HyperForm macro introduction Default macro menu Associated files (filenames and functions) Controlling the macro display using the HyperForm options panel Creating basic HyperForm macros HyperForm 7.0 Incremental Stamping Analysis 57

Appendix A: Macros What is a HyperForm Macro? A HyperForm macro is similar to a user-defined script or command file used to automate a HyperForm process or execute a series of steps semi-automatically. The HyperForm macro language is an extension of the HyperMesh/HyperForm command language. You can write simple macros that run from a HyperMesh/HyperForm command file, embed additional logic, and allow, by adding Tcl/Tk scripting commands, user interaction. The HyperForm macro language allows you to customize the macro interface by creating controls in the form of buttons and button groups. For each control you specify its characteristics. the macro page it displays on its label its location and size its help message the macro it calls, and any optional arguments Macros therefore have two parts, the definition of the button that activates the macro and the instructions the macro performs. Macros are interpreted, meaning that each command is completed in the order in which it appears in the macro file.. While macros offer a great deal of flexibility, once a macro is executed, there is no way to cancel the execution or reject the results. In addition, a macro may not be recursive (call itself). The Macro Menu The Macro menu is displayed on the right side of the graphics region when HyperForm is started. The macro menu contains four areas macro page selection buttons, display options, shortcut buttons, and tools buttons. The macro menu can be turned on or off, or a new menu can be loaded from the options panel through the menu config sub-panel. 58 Incremental Stamping Analysis HyperForm 7.0

Appendix A: Macros Files Associated with HyperForm Macros HyperForm macros have files (outlined below) associated with them. hf.cfg The display of the macro menu is controlled by a command in the HyperForm configuration file, hf.cfg. The macro menu is displayed (by default) when HyperForm is started. If you want to change the default and remove the macro menu from the screen display, delete the asterisk (*) before the *enablemacromenu() command. hf.mac This file defines the HyperForm macro menu. Its commands control the display and available operations of the macro menu. An hf.mac file may exist in the installation directory for HyperForm or in the directory from where HyperForm is launched. When HyperForm is started, it first looks in the directory from where it was launched and then in the installation directory for the hf.mac file. When the file is located, HyperForm reads it to define the attributes and contents of the macro menu. mac.cmf The mac.cmf file holds the commands of the last executed macro. HyperForm Options Panel The HyperForm Options panel (available from the permanent menu) contains the menu config sub-panel. This sub-panel allows you to turn the macro menu on and off as well as load your own macro menu file into HyperForm. HyperForm 7.0 Incremental Stamping Analysis 59

Appendix A: Macros HyperForm Macro Commands HyperForm macro commands reside in the default hf.mac file. When you open this file, you will see that it defines the macro menu contents in order by page. To change a macro on a given page, find that page in the hf.mac file and the macro name that you wish to modify. The attributes of a macro page that you can change include: the buttons displayed on a macro page. the location and size of the buttons appearing on a macro page. the label for each button. the help string displayed on the menu bar. the macro called by each button, with optional arguments to pass. Macros consist of valid command file or Templex commands, and are enclosed by the *beginmacro(macroname) and *endmacro() commands. Macros can accept data passed to them using the arguments $1, $2, etc. Each argument specifies where the values should be substituted. The following skeleton shows the format of a macro. *beginmacro(macroname) macro command statements go here *endmacro() 60 Incremental Stamping Analysis HyperForm 7.0

Appendix A: Macros To activate the macro from HyperForm, you must create a button on the macro menu that invokes the macro. Use the *createbutton()command to define the button and its characteristics. The syntax for this command is: *createbutton(page, name, row, column, width, COLOR, helpstring, macroname [, arg1 ]) Where: page Indicates the page number on which the button is to appear (values 1 through n; initially there are 4). name The text to display on the button. Enclose the text with quotes ( ). row The row in which to place the button (values 1 - n). column The column where the button starts (values 0-10). width The width of the button ( max 10). COLOR helpstring macroname arg1 The color of the button. The available button colors are: RED, BLUE, GREEN, CYAN, BUTTON, and MAGENTA. The color name must appear in capital letters. The string to be displayed in the menu bar when the button is selected. Enclose text of string in quotes ( ). The name of the macro to call when the button is selected. Enclose text of string in quotes ( ). Optional arguments passed to the macro. You can have as many arguments as your computer s memory will allow. HyperForm Macro Creation Process To assist in your creation of HyperForm macros, we suggest the following process. 1. Define the task. 2. Run through the process in HyperForm. 3. Add macro button commands. 4. Extract the commands from the command.cmf file. 5. Add them to the hf.mac file. 6. Modify necessary HyperForm commands and add macro wrapper commands. 7. Load the modified hf.mac file into HyperForm using options panel. 8. Test/Apply macro. HyperForm 7.0 Incremental Stamping Analysis 61

Appendix A: Macros Example 1: Creating a button This step in the creation of a macro allows you create and position the button that activates your macro. For this class, we create everything to appear on the macro menu. 1. Copy the hf.mac file from the../hf/bin directory into your working directory, the directory from where HyperForm is launched. Next, change the permissions of the local hf.mac file to writeable. 2. Open the hf.mac file from the working directory in a text editor and go to the bottom of the file. 3. Add the command: *createbutton(1, Test,20,5,5,MAGENTA, This is a test button for experience, macrosample ) To refresh your memory, here is the format for the *createbutton command and its arguments: *createbutton(page, name, row, column, width, COLOR, helpstring, macroname [, arg1 ]). Commands end with a hard return (press the ENTER key). Type each command until you get to the end of it, then press ENTER. If word-wrap is active, that is fine, as the macro processor only recognizes the hard return. 4. Save the modified hf.mac file. 5. Start HyperForm from the working directory. This will allow the new session to use the modified hf.mac file. 6. On the macro menu, you will see the Test button (defined in Step 3). Compare this button to our definition. It is magenta in color, begins in the middle of the row, and only goes half way across the macro menu.. There is no functionality behind the button at this time because the macro has not been written, but the button to activate the macro now appears on the macro menu. For a list of commands available to you for use in the construction of your macros, please refer to the HyperForm online help. 62 Incremental Stamping Analysis HyperForm 7.0

Appendix A: Macros Example 2: A macro to save the model Step 1: Define the task The first step in creating a macro is to know the process you want to automate. In this exercise, we want to create a one-button macro to automate saving the current HyperForm model to a file named temp.hf. The actions necessary to complete this task are: Leave the current panel. Enter the files panel. Enter the hf file sub-panel. Use the file= file browser to locate a directory and filename. Click save. Step 2: Run through the process in HyperForm We now execute the full process within HyperForm. Every command issued in HyperForm appears, in the order executed, in the command.cmf file. To see only the commands you are interested in placing in your macro, delete the current command.cmf file, then execute the commands necessary to complete the process. 1. Locate the command.cmf file. The file is in the specified working directory, which is the directory from which you started HyperForm. 2. Delete the command.cmf file. As soon as you begin working in HyperForm, all executed commands are written to the command.cmf file. If the file already exists, the commands are appended to the file. 3. From any page in HyperForm, select the files panel. 4. In the file = field, enter the filename temp.hf and select save. HyperForm 7.0 Incremental Stamping Analysis 63

Appendix A: Macros Step 3: Add the macro button command 1. Create an activation button in the macro menu to execute the macro. Our button will be placed on the macro menu. 2. Open the hf.mac file. 3. At the bottom of the file, change the *createbutton command created in the previous exercise to look like this. *createbutton(4, file save,20,0,10,green, Save the file, macrosave ) Step 4: Extract the commands from the command.cmf file 1. Open the command.cmf file using any text editor. 2. Locate the *writefile() command at or near the end of the command.cmf file. You should see the following. *writefile("temp.hf",0) This is the command that writes the model file. Step 5: Add the line to the hf.mac file 1. Select and copy this line to the hf.mac file. 2. On the line following the *createbutton() command in the hf.mac file, paste the *writefile() command copied from the command.cmf file. Your hf.mac file contains two lines: the *createbutton and *writefile. 64 Incremental Stamping Analysis HyperForm 7.0

Appendix A: Macros Step 6: Modify as necessary and add macro wrapper commands No modification is necessary to the line copied from command.cmf -- only the wrappers need to be added. 1. Following the *createbutton command, enclose the commands from the command.cmf file between *beginmacro() and *endmacro()commands and name the macro. macroname *beginmacro(macrosave) *writefile( temp.hf,0) *answer(yes) *endmacro() The macro name, macrosave, connects the button with the macro via the macroname field in the createbutton command. The command *answer(yes) handles the overwrite prompt in the event temp.hf already exists.. All HyperMesh/HyperForm commands can be found in the Commands Section of the HyperMesh/HyperForm on-line help. Argument definitions and examples are included. 2. Save the hf.mac file. HyperForm 7.0 Incremental Stamping Analysis 65

Appendix A: Macros Step 7: Load the new hf.mac file into HyperForm 1. Return to the HyperForm session, go to the options panel and select the menu config sub-panel. 2. Click on the macro file = button and locate the new hf.mac file and click retrieve to load the updated Macro menu.. Anytime a change is made to the macro menu, it must be retrieved through this panel to view or test the changes. 3. Press return. Step 8: Test/Apply macro 1. Click on the macro menu. A new button labeled "file save" should be on the menu. 2. Click file save to automatically save your file. The file is saved to the directory specified in the macro. Since no directory was specified in this case, HyperForm saves the file to the start-up or working directory. It will also have the naming convention used in the macro. Summary In this example, we created a macro to simplify the process of saving a HyperForm file. First we defined the process and executed it in HyperForm. Next, we created a button in the macro file, and then created the command file commands, including the appropriate heading and footer, and added them to the hf.mac file. Once we loaded the macro file into HyperForm, we tested it. 66 Incremental Stamping Analysis HyperForm 7.0