AutoForm–DieDesigner has been developed to generate tool concepts
in an early stage of tool design and to evaluate these concepts
by deep drawing simulation. The functions of AutoForm–DieDesigner
reflect these requirements
Automatic variable filleting of sharp geometry edges
• Powerful functions for determining the drawing direction
• Rapid solution for finding ideal part position of double attached parts Automatic and interactive filling of holes, boundary fill or generation of fill faces between double attached parts
• Modification of tool and part geometries
• Automatic or interactive generation or modification of a binder surface
• Automatic or interactive generation of outer or inner addenda
• Full parameterization
Furthermore, development and modification of tool surfaces can be
done very quickly. As for other AutoForm modules many processes
run in the background automatically without user intervention. For
complex parts the user can modify the automatic solution at any
time. Especially key profiles can be chosen arbitrarily.
AutoForm–DieDesigner is fully parametric: All user settings and
input are stored in the simulation file for easy modification. Similarly,
the parametric data structure allows for automatic redesign. If
the user changes the binder for example, all profiles are adapted to
the new geometry by pressing one button only. Even a full change
of part geometry is permitted, the entire addendum will change
automatically. Another target is automatic optimization of addendum.
AutoForm–Optimizer is fully integrated in AutoForm–Incremental,
AutoForm–OneStep and the user interface.
AutoForm–DieDesigner has not been developed to design a full
serial tool. The necessary surface quality should be ensured by
using a CAD–system. The required CAD–interfaces (IGES, VDAFS)
are implemented in this version to a large extent.
The current version 3.1 is the second DieDesigner–release. Despite
intensive research and development there are still a number of functions
which require further improvement. In detail these are:
• Automatically laid–out flanges
• Full implementation of symmetric parts
• More complex Addendum profiles
All these items are user requests and are currently under development.
Our team appreciates suggestions and will do its best to solve those problems.
This manual is designed to give the user practical advice in handling
AutoForm and achieving good calculation results. A number of
examples explain the design of typical tools step by step. In addition
to the overall features they will introduce the Curve editor for
designing and modifying lines globally and locally. Lesson six of
the AutoForm–Incremental workshop deals with automatic optimization
of tools generated with AutoForm–DieDesigner. The user
will be able to define an optimization and learn about the available geometry parameters.
Lesson 1 Basic Functions. . . . . . . . . . . . . . . . . . . . . . . . . .5
• Reading in the part geometry
• Basics on the addendum
• Profiles
• Master–Profile
• Individual profile
• Punch opening line
• Bar height line
• Exporting tool surfaces
Lesson 2 A simple Tool . . . . . . . . . . . . . . . . . . . . . . . .18
• Definition of the symmetry–plane
• Closing all holes (All holes)
• Boundary fill (Bndry fill)
• Generating a binder using Auto–Binder
• Generating a simple addendum
Lesson 3 Profile Orientation . . . . . . . . . . . . . . . . . . . . . . . .23
• Registers on the Prepare page
• Manual modification of the profile orientation
• Generating a binder using Auto–Binder
• Modifying the punch opening line
• Modifying the master–profile
• Generating individual profiles
• Generating a bar on the addendum
Lesson 4 From DieDesigner to Deep Drawing Simulation . . . . . . .36
• Boundary fill
• Generating a binder using Auto–Binder
• Changing the profile orientation
• Importing a binder surface
• Importing a punch opening line
• Smoothen the die radius
Creating a Binder Surface with Lesson 5
Auto–Binder and Manual–Binder.
• Generating a binder using Auto–Binder
• Generating a binder surface using Manual–Binder
• Generating and modifying binder–profiles
• Exporting of the binder surface and binder–profiles
Defining the Drawing Direction (Tip). . . . . . 55 Lesson 6
• Displaying backdrafts and drawing angles
• Defining the tipping center
• Automatic functions for the determination of the drawing direction
• Manual determination of the drawing direction
• Analyzing the drawing direction
Modification of Product and Tool Geometries . . . . . . .Lesson 7
• Outer trim
• Inner trim
• Global and variable filleting of sharp edges
• Overcrowning part and tool geometries
• Add detail
• Exporting fill faces
A Tool with Inner Binder and Inner Addendum . Lesson 8
• Importing a binder surface
• Generating an inner addendum
• Generating an outer addendum
Development of a Tool for Double–attached Part . . . . . . Lesson 9
• Mirroring left and right parts
• Defining a symmetry–plane for left and right parts
• Generating and modifying fill areas between double
attached parts
Generating a binder surface using Manual–Binder Using a simple part geometry, we describe the basic procedure for the generation of an addendum in AutoForm–DieDesigner. The part geometry is imported and a binder is generated automatically. We show that the parametrically generated faces will be adapted automatically, if the binder is modified. Finally, we describe the export of surfaces and curves.
Creating a new Simulation
User interface File > New
The New file dialog opens
Use the default settings for units and tolerance. Enter the following
file name:
File name: lesson1 > OK
The Geometry generator opens.
Reading the Part geometry
Select from the menu bar of the Geometry generator:
File > Import ... > af > OK > Files: dd_lesson_01.af > OK
The geometry is automatically assigned to the Part register. Simultaneously,
the geometry is shown in the main display and the Prepare
page of the Geometry generator is opened. Use the Display
part function to switch on/off the display of the Part register.
Note: A detailed description of the registers will be given in Lesson
3.
Generating the Part Boundary
To use the functions of the Geometry generator, the part boundary
must be available. Generate the part boundary by clicking
Apply Prepare
The part boundary is represented by a blue line
Part with Part boundary
Generating a binder surface using Auto–Binder
Go to the Binder page to generate the binder surface.
Auto > Apply
Generating an outer Addendum
In principle, you can generate inner and outer addenda with DieDesigner.
For this example, an outer addendum is needed.
Addendum Add addendum ... > Pick curve: Curve1 > OK
The Addendum page is shown in Fig. 1.4
The functions of the Addendum page will be described in Appendix
An ordinary drawing tool consists of the part geometry, the binder
surface and an addendum. In forming processes, the addendum in
general performs the task to make a suitable transition from the part
to the binder.
In AutoForm, the addendum is created on the basis of several profiles
The master–profile as shown on the Addendum page is the reference
profile for the individual profiles. The essential parameters of
the addendum (bars, radii and angles) are determined by the master–
profile. The heights and lengths vary for different distances
between the part and the binder.
In addition, it is possible to create any form of addendum by means
of modifying individual profile parameters.
Modifying the Master–profile
Modifying the Punch–Opening–Width
Modify the punch–opening–width on the Addendum page:
PO: 50 or alternatively Addendum
Click the vertical line and move it to about 50 mm > Apply
The tool is shown in the main display.
Enlarging the Binder surface
Go back to the Binder page:
Binder Adv > Min flange width: 200 > Apply
The binder surface has been enlarged, but the Addendum page is
shown in red. This is, because the addendum has not yet been connected
to the binder surface. Go to the Addendum page:
Addendum Apply
The tool with the new binder surface is generated.
Changing the Die radius
We will change the die radius in the lower left corner (from +zview). Switch on the display of all profiles. Go to the Addendum
page:
Addendum Options > Show all
Generating additional individual Profiles
To change the die radius it is necessary to define several individual
profiles and to modify them afterwards. The numbers of the individual
profiles may differ; the approximate position of the profiles
with respect to lower left corner of the part is important.
Definition of individual profiles:
Add prf … > Select > Profile: 64 > Add
Add prf … > Select > Profile: 68 > Add
Add prf … > Select > Profile: 75 > Add
Add prf … > Select > Profile: 79 > Add
Alternatively, select the profiles with the right mouse button:
Profile 64 > Add
Profile 68 > Add
Profile 75 > Add
Profile 79 > Add
The individual profiles should be as shown in Fig. 1.6
Individual profiles (marked red)
Note: Defined profiles can be copied: Select the profile with the
right mouse button and while holding the mouse button down drag
the profiles. Release the mouse button at the desired position.
Modifying individual Profiles or Die radius
Select Profile 75 on the Addendum page:
Advanced ... > Die radius: 10 > Return > Dismiss Addendum
Select Profile 68:
Advanced ... > Die radius: 10 > Return > Dismiss
and finally click on Apply
The addendum should be as shown in Fig. 1.7
Addendum after modifying the individual profiles
Note: Modifications on individual profiles only affect the neighboring
individual profiles.
The radii can be changed using the mouse: Select the arc line with
the left mouse button and while holding the mouse button down
drag the line. The respective radius is indicated above the profile window.
Creating a Bar
As described above four individual profiles have to be determined
in order to create the bar modification: The outer profiles (delimiters)
to fix the original state and the inner two profiles to be modified.
Modification will occur between the inner two profiles and
transition out to the original state at the outer profiles. In this case,
besides the existing Profile 79, three additional individual profiles have to be defined.
Definition of additional individual profiles:
Addendum Add prf … > Select > Profile: 83 > Add
Add prf … > Select > Profile: 96 > Add
Add prf … > Select > Profile: 100 > Add
Alternatively, select the profiles with the right mouse button:
Profile 83 > Add
Profile 96 > Add
Profile 100 > Add
Activate Profile 96 (Tab on the Addendum page or select the profile
in the main display). Select the rightmost profile template (Bar).
Note: All profile templates will be described in Appendix 3.
To modify the profile, click the horizontal line and move it to a
height of 10 mm or enter:
Heights: > Bar: 10
Do the same for Profile 83 and finally click on
Apply
Modifying the Bar
Activate Profile 96 and select the 5th profile template (Step). Do the
same for Profile 83 and finally click on
Apply
Addendum after modifying the bar
Modifying the Punch Opening Line
The punch opening line, which has been created automatically, will
be modified now. Use the command:
Lines ... > PO width: > Edit ... Addendum
The Curve editor opens. Use the right mouse button to click on a
node and drag it. The punch opening line is now modified. Points
can be added, deleted and moved in this way until the desired
punch opening line is displayed. ClickOK
to accept the line and then adapt the profiles to the new punch
opening line
Modified punch opening line
Alternatively, use the global modification mode of the Curve editor:
Addendum Lines ... > PO width: > Edit... > Global mod
Global modification parameters for the punch opening line
• Move the Convex slider to the right so that the PO line
becomes convex
Move the Expand slider to the right to expand the line.
Slide it back to 0.
• Move the Smooth slider to the right to smoothen the line.
Slide it back to 0.
Finally click: OK
Editing the Bar Height line
The bar height line is the highest point of the bar.
Switch on the display of all profiles. Go to the Addendum page:
Options > Show profiles Addendum
Only the individual profiles are displayed. To edit the bar height
line use the command:
Lines ... > Bar height: > Edit
Rotate the tool to a position as shown in Fig. 1.11. Click on the line
between the two points, which determine the bar (right mouse button)
and drag the point. The point can only be moved in the z–direction.
Move the point in such a way that a convex profile is formed.
Finally click onOK
The addendum is now adjusted to the bar height line.
Editing the Counter Bar Height–Line
The Counter bar height line describes the position of the counter bar
with respect to the part boundary. Rotate the model in such a way
that you view the bar from the part. You see that the transition of
the profile between part and bar is no longer plane but that it is
ascending due to modification of the bar height line.
Adjust the individual profiles 83 and 96
Addendum Heights: > CB: Free
and afterwards modify the CB line:
Lines ... > CB height: > Edit ...
Delete all the nodes between Profile 79 and 100 to smoothen the line
again. To do so click the nodes in the main display with the right
mouse button; press the Del key to delete the nodes. Finally click onOK
to get a plane addendum in this region.
The bar height line and the CB height line are used to smoothen
addendum regions and to get a uniform punch contact.
Changing the Drawing Depth
The default value for the drawing depth is 20 mm. This value is to
be changed. You can take advantage of the parameterized addendum
generation: All profiles are automatically adjusted to the new drawing depth.
Go back to the Binder page:
Binder Shift: 40 > Enter
Go to the Addendum page and click on
Addendum Apply
Exporting Tool Surfaces
The tool surfaces generated in DieDesigner can be exported in IGES
or VDAFS format:
The faces of the addendum are exported as follows:
Geometry Generator
File > Export surfaces … > Addendum
The binder surface is exported as follows:
File > Export surfaces … > Binder > Binder surface / Binder ring
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