Some parts contain „Feature lines“. These typical lines should continue in the addendum
of the tools with the same orientation to ensure a good material flow. This lesson
describes how to adjust or to change the profile orientation in DieDesigner
describes how to adjust or to change the profile orientation in DieDesigner
Tool for a decklidCreating a new Simulation
User interface File > New > File name: lesson3 > OK
Importing the Part Geometry (Left Part)
Only the left half of the part geometry is available in af format for this lesson.
Geometry Generator
File > Import > af > OK > Files: dd_lesson_03.af > OK
Defining the Symmetry–plane
For the generation of a complete tool the left half of the part has to
be mirrored. Define the symmetry–plane.
Prepare Symmetry / double …
Symmetry, half input > x-z-plane > y: 0 > OK
Mirrored part geometry
Flange Faces and the Register Deleted
In this decklid the license plate bay will be formed in a secondary
operation, i.e. this region is not considered for the generation of the drawing tool.
You can assign faces to the different registers on the Prepare page:
• Part: Contains the CAD faces for the part, which are
needed for the generation of the tool.
• Binder: Contains the faces of the part geometry, which are
placed directly on the binder surface. (The binder surface is
generated or imported on the Binder page later). This
should be used only if the complete tool surfaces have been
read in from CAD. Selected faces are then assigned to the Binder register.
• Flange: Register for CAD faces needed for subsequent operations.
• Deleted: Not used faces.
Select the faces of the license plate bay (Shift - right mouse but- Prepareton)
The selected faces are shown in yellow.
Part with the selected faces of the license plate bay repare Define objects: Deleted
Click the Deleted button to assign the selected faces to Deleted register.
The selected faces are no longer shown in the main display.
Use the button Display deleted to display the faces again.
Now we generate the part boundary.
Prepare Generate part boundary: Apply
Note: The part boundary is generated only for the faces assigned to the Part register.
No further information has to be entered on the Prepare page.
Closing Holes contained in the Part Geometry
go to the Modify P page. The remaining hole will be closed:
Modify P Add hole > Pick curve > Select the hole in the main display (rightmouse button) or from the lists > OK
Apply
The hole closed by fill faces.
If necessary, you can modify the fill faces by means of control
curves. Using control curves will be described in Lesson 7.
Generating a Binder Surface with Auto–Binder
Go to the Binder page.
Auto Binder
Define the settings of the binder on the Auto–Binder pages (some of
the default settings can be accepted). Make the following changes on the Binder page:
Drawing depth: Uniform > Surface profile: Max bndry slope: Binder
30.00 deg > Angle diff.: 30.00 deg > Flexibility: 0.70
Adv > Min flange width: 250 > Apply
The binder surface is generated automatically. For the modification
of the binder surface, the above setting can be changed. Click Apply to generate the new binder surface.
Generating the Outer Addendum
Add addendum ... Addendum
Only an outer addendum is needed for this decklid. Select the outer
curve with the right mouse button (in the main display) from the list.
Pick curve: > Curve 1 > OK
A new tab called Outer is added to the Addendum page.
Using a simple master–profile, the first version of the addendum is
generated. The distance between the part boundary and the punch opening line is set to 140 mm.
Addendum Widths > PO: 140 > Apply
The first version of the tool consisting of binder surface, addendum
and part is shown in the main display.
Adjusting Profile Orientation manually
The addendum consists of a number of profiles between the part
boundary and the punch opening line. The automatically defined
profile orientation is approximately perpendicular with respect to the part boundary.
For the decklid profile orientation has to be changed in certain areas. Go to the Addendum page and click on
Addendum Directions
Note: Adjust the view to positive z–direction to change the profile orientation by means of Directions.
Automatic profile orientation (green and red profiles) in the addendum
Procedure to change the Profile Orientation
• You see red and green profiles in the addendum. Clicking
the profile, the color changes from red to green and vice versa.
• Changes can be made to the red profiles. Drag the profile
with the right mouse button held down.
Note: After zooming in the relevant area, you get the best results by
clicking the right mouse button the red profiles as close as possible
to the punch opening line and by dragging them with the mouse button held down
• Changing a red profile, the changes are automatically valid
for the neighboring profiles. The changes are valid for the area limited by two red profiles.
• By clever determination of red and green profiles you can
locally arrange any profile orientation – adjusted to the feature lines.
Important: Changing the profile orientation, make sure that the profiles do not overlap.
For the decklid define the profile orientation as is in Fig. 3.6:
Modified profile orientation before confirming with OK
Having changed the profile orientation all along the addendum,
click on OK in the Direction dialog.
The addendum should be as is in Fig. 3.7:
Addendum after manual modification of the profile–orientation
Modifying the Punch Opening Line
In the bumper area of the decklid, the distance between the punch
opening line and the part boundary must increase to integrate a higher bar into this region.
Addendum Lines > PO width: Edit ...
Use the Curve editor to change the punch opening line, which should be as in Fig. 3.8:
Modified punch opening line before confirming in the Curve editor
Having accepted the changes in the Curve editor, the addendum is
automatically adjusted to the new punch opening line.
If no characteristic line needs any further modifications, close the
window using the Dismiss button.
Modifying the Master–Profile
To receive a uniform punch impact in the visual region of the part, a
bar must be provided for the whole addendum. Define the modification of the master–profile.
Note: To see an entire view of the master–profile in the display, it is
sufficient to click with the middle mouse button into the profile window.
Select the profile template (Bar).
Click the right side of the horizontal dashed line with the left mouse
button (in the profile window) and move it to approximately 20 mm bar height.
Set the option Bar in the area Heights to Bndr, to measure the
height of bar from the binder.
Enter the height of the bar:
Addendum Heights > Bar: 80
The master–profile should be as in Fig. 3.9:
Master–profile with bar
n addition, some radii and angles of the master–profiles have to be
adjusted to meet the requirements of the addendum for the decklid.
Addendum Advanced > Die radius: 8 > Wall angle: 15 > Punch radius: 35 >CB
radius: 30 > Enter > Dismiss
Note: Having entered this information, the respective changes can
be viewed in the profile window. Confirm each entry by pressing the Return key.
Adjust the circle radius with the mouse: Click the respective circle
with the left mouse button and click and drag the mouse to size the
circle. The current value of the radius is indicated above the display.
Finally, a counter bar is integrated into the master–profile: Move the
lower horizontal line down as far as possible.
The master–profile should be as in Fig. 3.10:
Master–profile with bar and counter bar
Click on the Apply button to generate the addendum based on the modified master–profile.
Apply Addendum
Plus–Parameter
The Plus parameters define a region of the addendum between the
profile parameters described above and the part boundary. The
Plus region determines the laid out flanges (for post operations). In
the case of the decklid, this is the region of the flange (hemming).
The Plus parameters are contained in the Advanced dialog.
Note: Detailed information on the Plus parameters will be given in
Appendix 3.
For the flange of the decklid enter:
Widths > Plus: 10 > Heights > Plus: 5 > Apply Addendum
An additional step is added to the addendum (near the part boundary).
Adding individual Profiles
In most of the cases an optimal addendum cannot be generated by a
master–profile only. Typically, an optimal addendum contains a
number of individual profiles. The generation of the individual profiles
is an integral part of the work in DieDesigner.
For the decklid, eight individual profiles differing from the master–
profile have to be added:
First, add the profiles without any changes, i.e. they use the same
settings as the master–profile.
Addendum Add prf … > Select > Profile: 1 > Add
Add prf … > Select > Profile: 223 > Add
Add prf … > Select > Profile: 309 > Add
Add prf … > Select > Profile: 349 > Add
Add prf … > Select > Profile: 381 > Add
Add prf … > Select > Profile: 398 > Add
Add prf … > Select > Profile: 401 > Add
Add prf … > Select > Profile: 414 > Add
Tabs with the profile number of the new profiles are added to Addendum page.
There are different procedures to generate and modify individual profiles:
• Use the mouse to generate an individual profile based on
automatically generated profiles.
• The automatically generated profiles are numbered circumferentially.
To insert a new individual profile, enter a profile number.
• Individual profiles can be copied, moved and deleted
using the mouse: Click an individual profile with the right
mouse button, move the profile with the mouse button
held down and finally release the mouse button. Move an individual profile outside the part to delete the profile.
Modifying Individual Profiles
An individual profile must be selected before it can be modified.
Select the profile by clicking it in the main display or by clicking the
respective tab on the Addendum page. Selected profiles are shown in yellow.
Change the profiles as described in the list below.
Prf 1 > as Master Addendum
Prf 223 > CB radius as small as possible (mouse)
Prf 309 > as Master
Prf 349 > Advanced > Punch radius: 40
Prf 381 > Advanced > CB radius: 39 > Punch radius: 44
Prf 398 > Advanced > CB radius: 55 > Punch radius: 60
Prf 401 > Advanced > CB radius: 52 > Punch radius: 52
Prf 414 > as Master
Apply
Generated addendum based on individual profiles
smoothing the Bar
The feature lines of the part proceed into the addendum. To
smoothen the regions of the addendum, change the bar height line.
Addendum Lines > Bar height > Edit ... > Change the line by moving or deleting
nodes until the result is as shown in Fig. 3.12
Procedure to change the bar height line:
• Click on a point (yellow) > Delete (to delete the point)
• Click on the line between two points to add a point
• Move a point with the right mouse button held down (z–direction)
Smoothed bar height line
Saving the Data
User interface File > Save
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