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Engineering Technology Associates, Inc 1133 E. Maple Road, Suite 200 Troy, MI 48083

DYNAFORM 5.2 Training Manual. Die Face Engineering. Engineering Technology Associates, Inc 1133 E. Maple Road, Suite 200 Troy, MI 48083 Tel: (248) 729-3010 Fax: (248) 729-3020 email: support@eta.com eta/DYNAFORM team November 15, 2004. Outlines. Introduction Tutorial I: Lift Gate

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Engineering Technology Associates, Inc 1133 E. Maple Road, Suite 200 Troy, MI 48083

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  1. DYNAFORM 5.2 Training Manual Die Face Engineering Engineering Technology Associates, Inc 1133 E. Maple Road, Suite 200 Troy, MI 48083 Tel: (248) 729-3010 Fax: (248) 729-3020 email: support@eta.com eta/DYNAFORM team November 15, 2004

  2. Outlines • Introduction • Tutorial I: Lift Gate • Basic procedures and techniques to generate an addendum • Tutorial II: Roof Bow • Tipping, Boundary Line Binder, Corner addendum and Direct Trim • Tutorial III: Exhaust Muffler • Flat Binder, Multi-Addendums and CAM Trim • Tutorial IV: Hood Inner • Inner Fill, Symmetry, Outer Smooth, Flat Binder and Auto Addendum • Tutorial V: Door Outer • Inner Fill, Inner Binder & Addendum, Morphing, Outer Binder & Addendum • Tutorial VI: Hyundai Fender • Inner Fill, Conical Binder, Addendum Edit and Drawbar

  3. Introduction • DFE (Die Face Engineering) • Early stage tool concept design based on part geometry • Evaluation of tool concept via virtual stamping • Parametric and Associative • Tool chest • Automatic variable filleting for sharp edges • Automatic or manual filling of holes, boundary fill and outer boundary smooth • Automatic or manual tipping and adjusting the drawing direction • Automatic and interactive generation or modification of a binder

  4. Introduction Tool chest continue… • Automatic and interactive generation or modification of outer and inner addenda • Morphing part or die geometries • Unfold flange function • Drawbar generation • Various trimming capabilities • Die design checking

  5. Introduction DFE GUI

  6. Introduction Modification Die Design Check Addendum

  7. Tutorial I Using the Lift Gate part, we describe the basic procedures and techniques for the generation of an addendum in DFE. The part geometry is imported and a binder and an addendum is generated automatically. We show that the parametrically addendum generation will be adapted automatically, if the binder is modified. Finally, we describe the export of surfaces and Binder Trim.

  8. Tutorial I Lift Gate DFE procedures: • Open and save database • Importing part geometry • Rename Part • Auto-Meshing the part • Create 2-Line Binder • Create master profile • Insert addendum • Modifying the Master-profile • Morphing the Punch Opening Line • Smoothing the Bar Height Line • Changing the local Die Radius • Profile orientation • Changing the Drawing Depth • Create addendum surface, PO line and Profile line • Binder trimming Lift Gate

  9. Tutorial I • Open and save database • Execute Dynaform 5.2 • For PC users: Double click on icon from the desktop • For Unix/Linux users: Type “df52 ” on the command line and hit the Enter key • Click on File and select Save As … (See Figure 1.1) • Type in “liftgate_(user name)_(date).df” as File Name • Click on Save • Import part geometry • Click on DFE(See Figure 1.2) • Select Preparation • Click IMPORT • File location: …/Tutorial1_Liftgate • File name: liftgate.igs • Click Ok to import the part geometry • Click Exit to dismiss DFE Preparation dialog window

  10. Tutorial I Figure 1.1

  11. Tutorial I Figure 1.2

  12. Tutorial I • Rename the Part • Click on Parts(See Figure 1.3) • Select Edit • Double click on the input box for Name to highlight Part C001V000 • Type in “LIFTGATE” • Click Modify • Click OKto dismiss Edit Part dialog window Figure 1.3

  13. Tutorial I iv. Auto-Meshing the surfaces • Select MESH TOOL (See Figure 1.4a) • Pick Tool Mesh in Mesher draw-down menu. (See Figure 1.4b) • Click on Select Surfaces icon (See Figure 1.4) • ClickDisplayed Surficon to select all the part geometry (See Figure 1.4c) • ClickOKto confirm surface selection • Key in Max. Size, 20.00 (mm) • Click Applyicon • Click YES to accept the mesh • Click Exit to dismiss Surface Mesh dialog window • See Figure 1.5 • Click on to save the database

  14. Tutorial I (a) (c) Figure 1.4 (b)

  15. Tutorial I Figure 1.5

  16. Tutorial I v. Create 2-Line Binder • Click icon to display isometric view • Click DFE (See Figure 1.6) • Select Binder • Select Binder Type: Two Lines Binder • Key in Binder Margin, 300.00 (mm) • Key in Binder Shift, 40.00 (mm) • Click Create to generate binder • Click Mesh Binder • Key in Max and Min Size, 100.00 (mm) (See Figure 1.6) • Click OK • Click Exit to dismiss Binder dialog window • Click on to save the database

  17. Tutorial I Figure 1.6

  18. Tutorial I vi. Create master profile • Click on DFE • Select Addendum • Click New (Master Profiles) (See Figure 1.7a) • Select Profile Type #3 (See Figure 1.7b) • Click Apply • Click Ok to dismiss Master Profile dialog window Do not close this dialogue, the next step will start from here. Note:The essential parameters of the addendum (bars, radii and angles etc) are determined by the master-profile. The heights and lengths vary for different distances between the part and the binder.

  19. Tutorial I (a) (b) Figure 1.7

  20. Tutorial I vii. Insert addendum • Click Assign (Addendum) (See Figure 1.8a) • Toggle off By Segment (default) (See Figure 1.8b) • Click Apply • Click Close to dismiss Insert Addendum dialog window • Addendum created on the basis of several profiles (See Figure 1.9 ) Do not close this dialogue, the next step will start from here. (b) (a) Figure 1.8

  21. Tutorial I Part Addendum Binder Figure 1.9

  22. Tutorial I viii.Modifying the Master-profile • Click Modify (Master Profile) (See Figure 1.10a) • Key in Die Radius, 10.0 (mm) (See Figure 1.10b) • Key in RBar Radius, 35.0 (mm) • Key in Part Radius, 10.0 (mm) • Key in PO Width, 120.0 (mm) • Key in Part Plus, 20.0 (mm) • Click Apply • Click Close to dismiss Insert Addendum dialog window • Addendum after modifying the Master is automatically updated. (See Figure 1.11 ) Do not close this dialogue, the next step will start from here.

  23. Tutorial I (a) (b) Figure 1.10

  24. Tutorial I Figure 1.11

  25. Tutorial I ix.Morphing the Punch Opening Line • Switch to the top view. • Toggle off Addendum Mesh and toggle on Profile (See Figure 1.12a) • Click Morph (Addendum) (See Figure 1.12a) • Toggle on POP Line (default) in the opens dialog. (See Figure 1.12a) • Click Apply. • Select a profile as Starting and one as Ending profile by sequence. (See Figure 1.12b) • In the opens question dialogue, click Yes button to accept the highlight region. (See Figure 1.12b) • Click the control point in the region and move it. (See Figure 1.12c) • Click close to dismiss the Morph Add… dialog and the addendum is automatically updated. • Toggle on Addendum Mesh • Toggle on Shade on the right bottom screen. • See Figure 1.13 to refer the Addendum after morphing the POP line Do not close this dialogue, the next step will start from here.

  26. Tutorial I (c) (a) (b) Figure 1.12

  27. Tutorial I Figure 1.13

  28. Tutorial I x.Smoothing the Bar Height Line • Switch to the isometric view. • Toggle off Addendum Mesh and toggle on Profile (See Figure 1.14a) • Click Smooth (Addendum) (See Figure 1.14a) • Toggle on Bar Height in the opens dialog (See Figure 1.14b) • click Apply. • Toggle on Through Fixed Point in the opens dialog (See Figure 1.14c) • Select a profile as Starting and one as Ending profile by sequence. (See Figure 1.15a) • In the opens question dialogue, click Yes button to accept the highlight region. (See Figure 1.15a) • Click the control point in the region and move it. (See Figure 1.15b) • Click close to dismiss the Smooth Add… dialog and the addendum is automatically updated. • Toggle on Addendum Mesh • Toggle on Shade on the right bottom screen. • See Figure 1.16 to refer the Addendum after morphing the bar Height Do not close this dialogue, the next step will start from here.

  29. Tutorial I (a) (b) (c) Figure 1.14

  30. Tutorial I (b) (a) Figure 1.15

  31. Tutorial I Figure 1.16

  32. Tutorial I xi.Changing the local Die Radius • Switch to the top view. • Click Modify (Profile) (See Figure 1.17a) • Select a profile as Starting and one as Ending profile by sequence. (See Figure 1.17b) • In the opens question dialogue, click Yes button to accept the highlight region. (See Figure 1.17b) • Click the Range button in the opens dialog. (See Figure 1.17c) • Select a profile (e.g. adjacent to the Starting profile) as Starting of the range and one (e.g. adjacent to the Ending profile) as end of the range in the region by sequence. (See Figure 1.17c) • Key in Die Radius, 30.0 (mm) in the opens profile dialog. (See Figure 1.18a) • Click Apply. • Click Close to dismiss profile dialog window • Addendum after modifying the Die Radius is automatically updated. (See Figure 1.18b ) Do not close this dialogue, the next step will start from here.

  33. Tutorial I Ending profile Starting profile Ending range Starting range (c) (b) Figure 1.17 (a)

  34. Tutorial I Die radius is changed (b) Figure 1.18 (a)

  35. Tutorial I xii.Profile orientation • Switch to the top view. • Click Orient (Profile) (See Figure 1.19a) • Pick a profile (See Figure 1.19b) • Move mouse cursor to a proper location • Click LMB (left mouse button) to complete • Repeat steps (c) to (e) until the profiles are evenly spaced • Refer to Figure 1.19c to compare the addendum • Click Close to dismiss the addendum dialog. Some parts contain “Feature lines”. These typical lines should continue in the addendum. Profile orientation is used to adjust the orientation of the addendum to ensure a good material flow.

  36. Tutorial I Before orientation (a) (a) (b) After orientation (c) Figure 1.19

  37. Tutorial I xiii.Changing the Drawing Depth • Switch to the isometric view. • Click Binder from DFE menu. • Click Move binder icon in the opens binder dialog. (See Figure 1.20a) • Key in the W box: 20.00 (mm) in the opens dialog. (See Figure 1.20b) • Click Apply. • You will see the value of binder shift changed from 40mm to 20mm and the binder move upward with 20.00mm along the Z-axis direction. (See Figure 1.20c) • Click Ok to dismiss the Move binder dialog. • Click exit to dismiss the Binder dialog. • Click Addendum from DFE menu to reopen the addendum dialog. • Click Update Addendum. • You will see that all profiles and addendum are automatically adjusted to the new drawing depth. (See Figure 1.21 ) This is the advantage of the parameterized addendum generation. Do not close this dialogue, the next step will start from here.

  38. Tutorial I (c) (b) Figure 1.20 (a)

  39. Tutorial I Figure 1.21

  40. Tutorial I xiv. Create addendum surface, PO line and Profile line • Click Surface icon locate at the bottom of the addendum dialog. (See Figure 1.22a) • Refer to Figure 1.22c, addendum surfaces are automatically created. • User can repeat the create surface step to generate the PO Line and Profile Line. • Click Close to dismiss Addendum Generation dialog window • Click on to save the database Note: The tool surfaces generated in DFE can be exported in IGES or VDAFS format, or in other popular CAD formats (e.g. UG, CATIA, pro/E ) through eta/CADTranslator module.

  41. Tutorial I Before create addendum surfaces After create addendum surfaces (b) (a) Figure 1.22 (c)

  42. Tutorial I xv. Binder trimming • Click Modification from DFE menu • Select BINDER TRIM (See Figure 1.23a) • Toggle off “surfaces” • Toggle off “Elements” • Toggle off “nodes” • Click Select icon (See Figure 1.23b) • Pick the displayed POP Line (See Figure 1.24a) • Click OK to confirm the selection • Click Apply • Click Yes in the opens question dialog (See Figure 1.24b) • Toggle on “Elements” • Toggle on “nodes” • Click Yes to dismiss Complete Binder dialog window • Click on to save the database • Turn off all parts and turn on C_BINDER (See Figure 1.24b) (a) (b) Figure 1.23

  43. Tutorial I Binder Trim Line Binder after trimming (a) (c) (b) Figure 1.24

  44. Tutorial II Roof Bow to show Tipping, Boundary Line binder, Corner addendum, Direct Trim (Part on binder application)

  45. Tutorial II Roof Bow DFE procedures : • Open and save database • Importing part geometry • Rename part • Auto-Meshing the surfaces • Check and repair meshes • Tipping • Create Boundary Line Binder • Create master profile • Insert addendum • Insert profile • Create corner addendum • Create addendum surface • Binder trimming • Generate trimline for Direct Trim application Roof Bow

  46. Tutorial II • Open and save database • Click on to create a new database • Click Yes to save the database • Click on File and select Save as … • Type in “roofbow_(user name)_(date).df ”as File name • Click on Save • Import part geometry • Click on DFE (see Figure 2.1) • Select Preparation • ClickIMPORT • Select File location: …/Tutorial2_RoofBow • Pick File name: roof_bow.igs • Click OK to import the part geometry

  47. Tutorial II Figure 2.1

  48. Tutorial II iii. Rename Part • Click on Parts (See Figure 2.2) • Select Edit • Double click on the input box for Name to highlight Part C001V000 • Type in “ROOFBOW” • Click Modify • Click OK to dismiss Edit Part dialog window Figure 2.2

  49. Tutorial II iv. Auto-Meshing the surfaces • Select TOOL MESH (See Figure 2.3a) • Click on Select Surfaces icon (See Figure 2.3c) • Click DisplayedSurf. to highlight all surfaces(See Figure 2.3b) • Toggle on Exclude (See Figure 2.3b) • Select binder surfaces (See Figure 2.4a) • Click OK to accept surfaces • Select Tool Mesh (See Figure 2.3c • Key in Max. Size, 20.00 (mm) • Click on Apply • Click Yes to accept mesh • Click Exit to dismiss Surface Mesh dialog window • See Figure 2.4b • Click on to save the database (a) (c) (b) Figure 2.3

  50. Tutorial II Mesh Highlighted Surfaces ! (a) (b) Figure 2.4

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