Exercise 1

Crossmember
 Exercise 1: Crossmember
Main Focus

General Functioning in the Designer Handling

der Software
Introduction of the Stage concept
First Steps of Geometry Generation
(Die Face stage)
First Steps of Evaluation
(Evaluation stage)

5
 Sheet Metal Forming Process Chain

Production Process Tool Design and

Concept, Styling Product Design Planning Engineering Manufacturing Tryout Part Production

Decision Drivers
Function

Cost

Quality

Lead Time

Tasks
Preliminary Part Release
Feasible Part Design for Planning and Draw-OP Engineering

Process Plan Release

Planning / Purchasing / Bidding for Process Engineering

Draw-OP Engineering / Draw-OP and Final Part Release

Advanced Feasibility for Process Design

Process Die Layout Release

Engineering for Process Design

Process Design Release

Process Design for Milling

Tool Buy-Off
Tryout Support for Part Production

Press Shop
Support

Process Maturity
10% 25% 50% 75% 90% 95%

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 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

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 Operationsfolge
OP20 D-20
Single action draw

OP30
Segmented outer trim T-30
15 x piercing in working direction

Leerstationen
OP40
Segmented outer trim
T-40
2 x cam trimming
13 x piercing in working direction

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 Import Part 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)

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 Import Part Import
Import of CAD Part Data
1 Import of the part data in the area Part Geometries: 1
Crossmember_Product_System.igs

The geometry is available in vehicle orientation.

It is generally recommended to import the CAD part data in
vehicle orientation!

10
 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) Pressendurch-
laufrichtung
Tool center is translated to the tip point of the part.

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 Material Material Definition
Definition of the Part Material

Material: HC300B.mat
Sheet thickness: 1.1mm (virtual slider)

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 Formchk Formcheck
Check the feasibility of the part and determine the
developed size of the part.

1 Select the option Develop Part.

2 Define to which side of the part the imported original

surface refer: Lower Side of Part 1

3 Start the Formcheck using Apply.

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 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:

14
 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 1
Click the big button Create Plan 2

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 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.

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 Plan Process 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.

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 Plan Process 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.

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 Plan Process Plan
1 Activate the automatic rounding for the cam
directions of the cam trims
Cam 1 and Cam 2.

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 Plan Trim Segmentation
Trim Plan

Define the trim segmentation specified in the process plan:

T-30 T-40

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 Plan Trim Segmentation
Trim Plan

Correction Options of the Segmentation

Trim Plan Editor or
Context menu:
Context menu in the main window Manual movement of the trim
segments to the available
working directions and cams
(if available).

Auto Assign:
Alternately assigns the trim segments to the
first two trim operations.

21
 Plan Trim Angle Analysis

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?

22
 Piece Cost Piece Cost Determination
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.

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 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.

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 Die Face Stage
The Die Face stage is the central place for the Directly go to the drawing operation D-20.
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.

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 D-20 Modify Fill Holes
Fill all holes on the Modify page.

1 Fill all holes.

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 D-20 Modify Edit Part Boundary
1 Fill the boundary areas of the Part Boundary curve with
an automatic Outer Fill.

2 Define a Roll Radius of 1000 mm.

Confirm by clicking Apply. 1

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 D-20 Modify Edit Part Boundary
Change the automatic fill surfaces to manual fill
surface for the reworking.

Edit these fill surfaces by adding additional profiles.

Start with the fill surface Manual Fill 22 1 and add
control elements. 2

4 3
5 2 1

6 1

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 D-20 Modify Edit Part Boundary
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.

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.

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 D-20 Modify Curve Editor
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:
permanent
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

Copied
Copying normals normal of
Keyboard shortcut + click on Face copies the normal of the surface
the selected 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

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 D-20 Modify Edit Part Boundary
Result of modified fill surfaces 1 and 6

6 1

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 D-20 Modify Edit Part Boundary
Manual modification of the areas 2, 3, 4 and 5

4 3
5 2 1

6 1

Delete the fill surfaces for 2 and 3:

1 Select the fill surfaces.
2 Click on Delete Selected.

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 D-20 Modify Edit Part Boundary
Adding a manual fill surface

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 D-20 Modify Edit Part Boundary
Adding a radius
1 Select the point of intersection
2 Define the radius: 60 mm
3 Re-calculation of the fill surfaces

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 D-20 Modify Edit Part Boundary
Result of the modified fill surfaces 2, 3, 4 and 5

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 D-20 Binder Binder Generation
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

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 D-20 Binder Binder Modification

Translate the binder by 35 mm in z direction.

Shift: 35.00 mm (global)

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 D-20 Addendum Addendum

Closes the gap between the part and the binder surface.
Is required for the separation the die surface into punch
and binder.

Generate an addendum along the Part Boundary.

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 D-20 Addendum Addendum
Punch Opening

Edit the punch opening by smoothing the Punch Opening

Width curve.
Punch Opening Width: Modification: Convex: 20mm

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 D-20 Addendum Addendum
Modification of the Profile Parameters

Die Radius: 10 mm (double click on circular arc)

Bar Radius: 15 mm

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 D-20 Addendum 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.

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 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.

Check whether your model is green.

2 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.

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 D-20 Trimchk Trim Angle Analysis
Trimcheck

Analyze the trim lines for the feasibility of the trim.

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 D-20 Formchk Formcheck
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 optimally stretched part

with only a few small areas of potential failure.

44
 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 Rolling
Is defined relative to the press flow direction direction
Important for anisotropic materials (check the correct
definition)
Positive angles, counterclockwise
Press flow direction

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 Blank Definition
Blank
Define the blank shape based on the Formcheck calculation.

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 PL Process Stage
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

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 PL Process Stage
Reference Side

Define to which side of the tool the imported original surfaces

refer.

Press Stroke: 700.00 mm

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 D-20 Tools Binder Position
Cushion Stroke

Modify the Cushion Stroke in such a way that the binder is

positioned above the punch.

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 D-20 Drawbeads 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 re-
calculated 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.

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 M-50 Springback
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.

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 Control Simulation
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.

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 Splits Evaluation
Evaluation Stage

Central place for the evaluation of the simulation

Allows for the systematic evaluation of failure and part
quality.
Start with the evaluation of the result variables
Splits (Formability, Max Failure, Thinning)
Draw-In

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 Splits Failure
Max Failure

54
 Splits Failure
Thinning

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 Draw-In 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.

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 Springback Springback
Normal Displacement

57