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ENV20 - EXERCISE 6
Exercise 1 Crossmember
Exercise 1: Crossmember •
Main Focus •
•
•
•
General Functioning in the Designer – Handling der Software Introduction Introduction of the Stage concept First Steps of Geometry Generation (Die Face stage) First Steps of Evaluation (Evaluation stage)
Exercise 1: Crossmember •
Main Focus •
•
•
•
General Functioning in the Designer – Handling der Software Introduction Introduction of the Stage concept First Steps of Geometry Generation (Die Face stage) First Steps of Evaluation (Evaluation stage)
Sheet Metal Forming Process Chain Concept, Styling
Process Engineering
Production Planning
Product Design
Tool Design and Manufacturing
Tryout
Part Production
Decision Drivers Function Cost Quality Lead Time
Tasks Preliminary Part Release for Planning and Draw-OP E ngineering
Feasible Part Design
Process Plan Release for Process Engineering
Planning / Purchasing / Bidding
Draw-OP and Final Part Release for Process Design
Draw-OP Engineering / Advanced Feasibility Process Engineering
Die Layout Release for Process Design Process Design Release for Milling
Process Design
Tool Buy-Off for Part Production
Tryout Support
Press Shop Support
Process Maturity 10%
25%
50%
75%
90%
95%
Part Info •
•
•
Part Info •
Crossmember
•
ca. 1500 mm x 425 mm
Material •
HC300B
•
Sheet thickness: 1,10 mm
Process Plan Info •
OP20: Single action draw
•
OP30: First trim
•
OP40: Second trim
Operationsfolge •
OP20 •
•
•
D-20
Single action draw
OP30 •
Segmented outer trim
•
15 x piercing in working direction
OP40 •
Segmented outer trim
•
2 x cam trimming
•
13 x piercing in working direction
T-30
T-40
n e n o i t a t s r e e L
Part Import
Import •
Import of CAD Part Data •
•
It is recommended to import the CAD part data in vehicle orientation.
Supported Formats: •
IGES File (*.igs)
•
.step (*.step)
•
VDA File (*.vda)
•
.stp (*.stp)
•
AF File (*.af)
•
.* (*.prt.*)
•
.nas (*.nas) – Mesh only
•
.jt (*.jt)
•
STL File (*.stl) – ASCII only
•
sldprt (*.sldprt)
•
.CATPart (*.CATPart)
•
sldasm (*.sldasm)
•
.CATProduct (*.CATProduct)
•
.x_t (*.x_t)
•
.cgr (*.cgr)
•
.x_b (*.x_b)
•
.model (*.model)
•
.exp (*.exp)
•
.session (*.session)
•
.prt (*.prt)
•
.sat (*.sat)
•
.unv (*.unv)
•
.arc (*.arc)
Import •
Part Import
Import of CAD Part Data 1 Import of the part data in the area Part Geometries: •
Crossmember_Product_System.igs
•
The geometry is available in vehicle ori entation. It is generally recommended to import the CAD part data in vehicle orientation!
1
Tip •
Automatic Tipping
Tipping the Part Data •
The part is tipped from vehicle orientation to an orientation suitable for production on the Tip page.
•
Use Automatic Tipping function to tip the part.
•
The following functions are automatically performed: •
•
•
•
Translation of the press coordinate system to the center of gravity of the part The part considering all surface patches is orientated with the average normal vector with respect to the press working direction. Orientation of the part with minimal width in press flow direction (tipping about the z axis) Tool center is translated to the tip point of the part.
Pressendurchlaufrichtung
Material Definition
Material •
Definition of the Part Material
•
Material :
HC300B.mat
•
Sheet thickness:
1.1mm (virtual slider)
Formcheck
Formchk •
Check the feasibility of the part and determine the developed size of the part.
1 Select the option Develop Part. •
2
•
3
•
Define to which side of the part the imported original surface refer: Lower Side of Part
1
Start the Formcheck using Apply.
2
Formchk •
Results Formcheck
First fast estimation of the feasibility of the part / Indication of possible problematic areas. 1 Select the option Feasibility Diagram. •
2 Analyze the results for the optimal holding conditions: •
1
2
Plan Stage General The Plan stage is the central place for the planning of the forming process (operations and manufacturing steps). •
Plan Creation •
Start with a predefined operation sequence.
•
Select the option Single Action Draw, Trim, Measurement
•
Click the big button Create Plan
2
1
2
1
Production •
Adaptation of the Operation Sequence
Adapt the operation sequence to the specified process plan. •
Extend the sequence on the transfer press by a second trim operation.
•
Move the Trim icon under Operations behind T-30.
Plan •
•
•
•
On the Plan page the features to be manufactured assigned to the individual operations. When switching to the Plan page the holes in the part are automatically detected. All holes are automatically assigned to the trim operation T-30 as feature Piercing. Piercings are automatically assigned to Bundles.
Process Plan
Plan •
Move the cam trims and piercings colored purple in the picture below to T-40, by moving the corresponding Processing Units to operation T-40.
Process Plan
Plan
Process Plan
1 Activate the automatic rounding for the cam
•
directions of the cam trims Cam 1 and Cam 2.
1
1
Trim Segmentation
Plan •
Trim Plan •
Define the trim segmentation specified in the process plan:
T-30
T-40
Plan
•
Trim Plan
•
Correction Options of the Segmentation •
Trim Plan Editor or
•
Context menu in the main window
Auto Assign: Alternately assigns the trim segments to the first two trim operations.
Trim Segmentation
Context menu: Manual movement of the trim segments to the available working directions and cams (if available).
Plan
•
Perform a trim angle analysis.
•
The analysis is realized at the original part boundary curve.
•
•
The combined trim and shear angle analysis indicates the Worst Case (worst result of both analyses).
Which areas are problematic taking into account the general requirements?
Trim Angle Analysis
Piece Cost •
•
•
Determine the piece costs based on the existing process plan.
Change the Robustness Level and the value for the Total Production Volume. Check the effects on the piece costs.
Piece Cost Determination
Reporting •
Start the report generation for the process plan. 1
•
•
Open a template for the process plan: ProcessPlan_Template.afr AutoForm-ReportManager opens in Template mode.
1 Update the template with your current design file. •
•
Now you are in Report mode.
•
Export the file in PDF format.
Die Face Stage •
•
•
•
The Die Face stage is the central place for the generation the active surfaces of all forming tools for the import of the part geometry.
All operations on the Die Face stage have already been defined by the process plan.
Sequentially process the operations from the left to the right.
No modifications are introduced for the Measuring operation and the two trim operations.
•
Directly go to the drawing operation D-20.
D-20 •
Fill Holes
Modify
Fill all holes on the Modify page.
1 Fill all holes. •
1
D-20
Edit Part Boundary
Modify
1 Fill the boundary areas of the Part Boundary curve with •
an automatic Outer Fill.
2 Define a Roll Radius of 1000 mm.
•
2
•
Confirm by clicking Apply.
1
D-20 •
Edit Part Boundary
Modify
Change the automatic fill surfaces to manual fill surface for the reworking.
2
•
Edit these fill surfaces by adding additional profiles. Start with the fill surface Manual Fill 22 1 and add control elements. 2
5
3
4
2 6
1
1
D-20 •
Edit Part Boundary
Modify
Select the Start or End point. •
Profile normal to the boundary curve 1 Apply the condition Normal to Boundary of the Curve Editors at the boundary of the fill surface to make sure that the profile normally contacts the boundary of the fill surface. •
1
2 Course of profile tangential from existing curve •
•
•
Using the short cut + Click on Curve (curves and edge of objects) the tangent of the clicked point of a curve is copied to the profile.
Hint: By a double click on the line segment you switch between Straight and Curved.
D-20 •
Curve Editor
Modify
Curve Editor – Tangents / Normals •
Working with Start and End points •
•
•
Permanent boundary conditions can be defined for the tangents of Start and End points of the profiles: •
Normal to Boundary
•
Tangential to Boundary
The keyboard shortcut + click on Curve (curve and solid edges) copies the tangent of the selected point of a curve.
Working with inner points •
permanent
Copying normals •
Keyboard shortcut the selected surface.
Copied normal of + click on Face copies the normal of the surface + Click on Face
•
Copying tangents •
•
Keyboard shortcut + click on Curve translates the point to the tangential elongation of the selected point on the curve. Keyboard shortcut + Click on Face translates the point to the tangential elongation of the selected point of the surface.
+ Click on Face
D-20
Edit Part Boundary
Modify
Result of modified fill surfaces 1 and 6
6
2
1
D-20 •
Manual modification of the areas 2, 3, 4 and 5
5
3
4
1
2 6
•
Edit Part Boundary
Modify
1
Delete the fill surfaces for 2 and 3: 1 Select the fill surfaces. •
2 Click on Delete Selected. •
2
D-20 •
Edit Part Boundary
Modify
Adding a manual fill surface
1 2
D-20 •
Edit Part Boundary
Modify
Adding a radius 1 Select the point of intersection •
2 Define the radius: 60 mm •
3 Re-calculation of the fill surfaces •
3 1
2
D-20
Modify
Result of the modified fill surfaces 2, 3, 4 and 5
Edit Part Boundary
D-20 •
Binder
Binder •
Generate an automatic binder.
•
Settings
•
•
Binder Wrap: Single Curved
•
Orientation Mode: Single Curved
Control Element •
Control Curve: Copy of Part Boundary at the end of Modify
•
Weight: 0.80
Binder Generation
D-20
•
Binder
Translate the binder by 35 mm in z direction. •
Shift:
35.00 mm (global)
Binder Modification
D-20
•
•
•
Addendum
Closes the gap between the part and t he binder surface. Is required for the separation the die surface into punch and binder.
Generate an addendum along the Part Boundary.
Addendum
D-20 •
Addendum
Punch Opening •
•
Edit the punch opening by smoothing the Punch Opening Width curve. Punch Opening Width: Modification: Convex: 20mm
Addendum
D-20 •
Addendum
Modification of the Profile Parameters •
Die Radius:
10 mm (double click on circular arc)
•
Bar Radius:
15 mm
Addendum
D-20 •
Addendum
Modification of the Profile Directions •
•
The automatically generated profile are as far as possible normal to the part boundary. Adjust the profile direction in the marked areas below accordingly.
Addendum
D-20 •
Verification of the Surface Quality
CAD Export 1 Color Exportable indicates, which CAD surfaces can be exported: •
•
•
Green: CAD surfaces are available for export.
1
Red: CAD surfaces are not available for export. You have to rework the geometry to make the export possible.
2
•
2
Check whether your model is “green”. export of the model in IGES format: •
During import into a CAD system it is usually possible to combine the surfaces with a tolerance of 0.03 mm.
D-20 •
Trimchk
Trimcheck •
Analyze the trim lines for the feasibility of the trim.
Trim Angle Analysis
D-20 •
Formchk
Check of the Feasibility •
•
•
Consideration of addendum and binder causes a more precise quality of the results. Estimation of the minimal blank size
The restraining of 0.35 results in an optima lly stretched part with only a few small areas of potential failure.
Formcheck
Blank Definition •
Blank •
•
Definition of the blank outline, Symmetry option (blank), position and rolling direction
Symmetry •
•
•
No Symmetry: Calculation is realized with the entire blank (asymmetrical blank) Left/ Right Side: Calculation is realized with the half blank Full: Entire blank with symmetry
Position •
Defines the z position of the blank
+ •
Roll Angle •
•
•
Is defined relative to the press flow direction
Rolling direction
Important for anisotropic materials (check the correct definition) Positive angles, counterclockwise Press flow direction
Blank Definition •
Blank •
Define the blank shape based on the Formcheck calculation.
1
2
PL •
•
Definition of Tool Offset •
Defines the reference side of the imported geometry
•
Defines the direction of the tool offset
Drawbead Settings •
Represents the design guideline for drawbeads
•
Basic settings for drawbead design in the Drawbead Generator
•
Defines how the design reacts on dimensional changes
Process Stage
PL •
Reference Side •
•
Define to which side of the tool the imported original surfaces refer.
Press Stroke: 700.00 mm
Process Stage
D-20 •
Tools
Cushion Stroke •
Modify the Cushion Stroke in such a way that the binder is positioned above the punch.
Binder Position
D-20
•
Drawbeads
Circumferential Drawbead for OP-20 •
Generate a drawbead.
•
Apply the Adaptive Line Bead model:
It is a line bead model which takes into account the real drawbead profiles. The current restraining force and uplift force is constantly recalculated based on these profiles during the simulation. Sheet thickness reduction and bending strain due material flow caused by the drawbead is taken into account. •
•
Use the Punch Opening Curve for the definition of the circumferential drawbead. Expand this curve by 25 mm. Use a Round profile.
Drawbeads
M-50
•
Free Springback •
•
Define free springback for the Measuring operation M-50. Gravity is not taken into account for free springback.
The trim operations T-30 und T-40 have already been defined based on the Plan stage. The trimmings have automatically taken over.
Springback
Control •
Simulation Stage •
•
•
Central place for the definition of simulation parameters and the setup as well as start the simulation calculation Change the Control Parameter settings to Engineering Phase CE+ (Concept Evaluation+ ), because an analysis of springback behavior is to be realized. EPS-5 (Elastic Plastic Shell element, 5 Layers) is applied for that purpose.
Simulation
Splits •
Evaluation Stage •
•
•
Central place for the evaluation of the simulation Allows for the systematic evaluation of failure and par t quality. Start with the evaluation of the result variables •
Splits (Formability, Max Failure, Thinning)
•
Draw-In
Evaluation
Splits •
Max Failure
Failure
Splits •
Thinning
Failure
Draw-In •
Draw-In Evaluation
•
•
•
Available for drawing stages The definition of a reference time step is necessary. Draw-in measurement starts at this reference time step By default the measurement is realized after binder closing.