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Die Face Engineering. DYNAFORM 5.7.3 Training Tutorial. Tutorial VII. Functions for Double Attach in DFE Module and run incremental analysis with Inc Solver. Create and Save Database. Click File menu and select Save as (See Figure 1). Enter the file name: DoubleAttach_(user name)_(date).df

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Die Face Engineering

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    1. Die Face Engineering DYNAFORM 5.7.3 Training Tutorial

    2. Tutorial VII Functions for Double Attach in DFE Module and run incremental analysis with Inc Solver

    3. Create and Save Database • Click File menu and selectSaveas (See Figure1). • Enter the file name:DoubleAttach_(user name)_(date).df • ClickSaveto save the database (See Figure 2). Figure 1 Figure 2 3

    4. Import Part Geometry • Click DFE(See Figure 3). • SelectPreparation. • ClickIMPORTbuttononDefinepage (See Figure 4). • Select file location: … • Import the left side part first and select file: da.igs • Click Okbutton to import the part geometry Figure 3 Figure 4 4 Figure 5

    5. Rename Part • ClickParts • SelectEdit(See Figure 6). • Select the redpart and double click the input box for Name. • Enter the new name LHSIDE. • ClickModifyafter modification. • Use the same method to change part Greento RHSIDE. • ClickOK to exit Edit Part dialog box. Figure 6 Figure 7 Figure 8 5

    6. IV.Auto-mesh Surfaces • Select DFEPreparation. • ClickSurface Mesh(See Figure 9) and toggle onIn Original Partin the displayedsurface Meshwindow. ClickSelect Surface(See Figure 10). • ClickDisplayedSurf.button to select all the surfaces displayed on the screen (See Figure 11). • ClickOKto confirm the selected surfaces. • Return toSurface Meshwindow. • Key in the Max. Size: 20.00(mm) • ClickApplyto mesh. • ClickYesto accept the mesh (See Figure 12). • ClickExitto exit the Surface Mesh dialog box. • Save the database. 6

    7. Figure 11 Figure 9 Figure 10 7

    8. IV.Auto-mesh Surfaces Figure 12 8

    9. V.Check and Repair Mesh • Toggle offSurface. • SelectDFE PreparationModel Check/Repair(See Figure13). • Click Boundary Display icon (line one, column two) (See Figure 14). • Toggle off Elements and Node. • Click (Free rotation) to rotate the model. • Click (Clear highlight) to make sure that every part has only one complete outer boundary line. If there is gap in part, edit the single mesh until there is no interior gap (See Figure 15). • Click to display the model in isometric view. • ClickAuto Normalicon(line one, column one). • SelectCURSOR PICK PARTand move the cursor to select an element on the model. • As illustrated in Figure15, change the normal direction of all elements to the future stamping direction. • ClickExitto exit the dialog box. • ClickOKto exitModel Check/Repairdialog box. 9

    10. V.Check and Repair Mesh Figure 14 Figure 13 10

    11. V.Check and Repair Mesh Rhsideelement direction Lhsideelement direction Figure 15 11

    12. VI.Define Left and Right Parts • ClickDfe PrepatationSymmetry/DoubleAttach. • Click Left/Right,Full Inputbutton underDouble Attach(See Figure 16). • Click Select button underLeft Part (See Figure 16). Select Lhside in the displayed window (See Figure 17) to define the left part. • Click Select button under Right Part and select Rhside in the displayed window to define the right part. • If the boundaries of two parts are symmetrical, the system will enter the defined left part name to the textbox under Left Part and enter the defined right part name to the textbox under Right Part (See Figure 18). • Display the symmetrical axis between two parts in 3D view (See Figure 19). 12

    13. VI.Define Left and Right Parts Figure 17 Figure 18 Figure 16 13

    14. VI.Define Left and Right Parts Figure 19 14

    15. VII.Tipping • ClickDFE PreparationTipping. • Click the fourth button tip left,sync. right underGeneral/DoubleAttach, which means to tip the right part automatically when tipping the left part (See Figure 20). • Enter the rotation center (1600,-700,900) of the left part under Tipping Center. • Enter the rotation axis and angle of each time under Manual: The first time: rotation axis:U Axis, rotation angle:22°. Click the button (See Figure 20). The second time: rotation axis:W Axis, rotation angle:15°. Click the button (See Figure 22). The third time: rotation axis:V Axis, rotation angle:9°. Click the button (See Figure 24) • Considering the interconnection of two parts and the feeding direction, rotate the left part 90°about U Axis and rotate 90°about W Axis. The final Topview is shown in Figure26 and 27. • As shown in the figure, the distance between the left part and right part is too large to generate addendum. Therefore, the distance needs to be narrowed. • Rotate V Axis under Manualand enter the moving distance 625 of a single part in the input box for Step. Click button . The final top view is shown in Figure 28 and 29. • Click Exitto exit Tippingpage and save the database. 15

    16. VII.Tipping Figure 21 Figure 20 16

    17. VII.Tipping Figure 23 Figure 22 17

    18. VII.Tipping Figure 25 Figure 24 18

    19. VII.Tipping Figure 27 Figure 26 19

    20. VII.Tipping Figure 29 Figure 28 20

    21. VIII. Create Addendum between Left and Right Parts • Click Boundary FillDouble Fillin theDFE Preparationwindow. • ClickAdjust Bdy-Pointbutton and select nodes on the boundary. Adjust the addendum region between the left and right parts (See Figure 31) and click the middle mouse button to confirm. • The system automatically generates 7 control lines in the addendum region between the left and right parts and lists them in the Control Lines list box by sequence (See Figure 30) • ClickDelete button and select Cntrl ln 5 and Cntrl ln 6to delete these two control lines. Click the middle mouse button to confirm (See Figure 32and 33). • Click Add button and select three nodes in the addendum region to add three control lines. Click the middle mouse button to confirm (See Figure 34and 35). • ClickApply button to automatically generate addendum and mesh at the juncture of the left and right parts and name it as Double (See Figure 36 ). • ClickExit to exitDouble Fillpage. 21

    22. VIII. Create Addendum between Left and Right Parts Figure 31 Figure 30 22

    23. VIII. Create Addendum between Left and Right Parts Delete two control lines Figure 33 Figure 32 23

    24. VIII. Create Addendum between Left and Right Parts Add three control lines Figure 35 Figure 34 24

    25. VIII. Create Addendum between Left and Right Parts Figure 36 25

    26. IX.Inner Fill • Click Boundary FillInner Fillin theDFE Preparationwindow. • Select Type:Auto Fill(See Figure 37). • Enter Hole in the input box for To Part, which means to put the filled hole in Hole layer. • ClickApply button and click the middle mouse button confirm the selected inner hole. The system automatically fills the inner hole (See Figure 38). • Click Exit to exitInner Fillpage. 26

    27. IX.Inner Fill Figure 38 Figure 37 27

    28. X.Create and Modify Binder • ClickDFEBindermenu and clickCreate page. • Select the first type Flat Binder as binder type. Key in margin: 100and Shift:20. ClickApplyto generate flat binder automatically (See Figure 39). • Click Modifyto modify the created binder. Click Add to add section. Do not toggle on By Inputoption. Click Create button (See Figure 40) to create a vertical section line in the middle of part (See Figure 41). The system will name it Ctrl Ln0 automatically. • Use the same method to create a horizontal section line. The system will automatically generate a section line at the symmetrical position of the right part and name it as Ctrl Ln1 (See Figure 42). • Select Ctrl Ln1and clickEditto edit it. Set 3D view as the front view simultaneously. Change the Z coordinate value for the left and right control points of horizontal section to 15 (See Figure 43). It will be previewed in 3D view after pressing Enter (See Figure 44). If it meets the binder requirements, click Apply to confirm and click Close to exit. • ClickApplyto modify binder automatically according to the new section line. • Return toCreatepage and click Meshto mesh binder. Enter 30 as the max. and min. mesh size. Click OK to confirm (See Figure 45) and click Exit to exit the Binder window. 28

    29. X.Create and Modify Binder Figure 39 Figure 40 29

    30. X.Create and Modify Binder Figure 41 Figure 42 30

    31. X.Create and Modify Binder Figure 44 Figure 43 31

    32. Figure 45 X.Create and Modify Binder 32

    33. XI.Create Addendum • Click DFEAddendummenu and click New button underMaster Profiles(See Figure 46). • In the displayed Master window, select the second icon as the Profile Type. Use the default values except changing Plus Part=10 (See Figure 47). Click OK to add the profile named Master 1to Profiles list box (See Figure 48). • Click Assign button under Addendum (See Figure 49). ClickApplyin the displayed dialog box (See Figure 50). The system will automatically generate addendum around part (See Figure 51). Click Close to exit. Add the addendum named Addendum1 into the Addendum list box. • Since the POP Lineof the part seems to be uneven, the addendum should be modified. Do not exit Addendum Generationwindow. 33

    34. XI.Create Addendum Figure 46 Figure 47 Figure 48 34

    35. XI.Create Addendum Figure 50 Figure 51 Figure 49 35

    36. XII.Modify POP Line • Click Modify button underAddendum (See Figure 52). • SelectSmoothPOP Lineand click Apply(See Figure 53). • Select Through Fixed Points in the displayed Smooth window and click Select Fixed Pointsbutton (See Figure 54). • Select the top two fixed points and the bottom two fixed points on the left side of POP Line. Click Preview (See Figure 55). • Click Apply to update POP Lineautomatically. Click OK to exit Smooth window. Click Update Addendum Meshto update the new addendum (See Figure 56). 36

    37. XII.Modify POP Line Select four nodes Figure 53 Figure 52 Figure 55 Figure 54 37

    38. XII.Modify POP Line Figure 56 38

    39. XIII.Modify Profile of Addendum • Click Orient button under Profile (See Figure 57). • Keep the default option By PO Pointin the displayed Orient Profilewindow. Click Apply button (See Figure 58). • Select a profile outside the fillet which is at the lower left corner of part (See Figure 59). Adjust its direction to keep consistency with the direction of part’s feature line (Figure 60). Click the middle mouse button to exit after adjustment. • Select By Ref Profile in Orient Profilewindow and click Apply button (See Figure 61). Select the adjusted profile as the reference profile and then select the profile to be modified. The system will automatically modify the direction of the selected profile to the reference profile direction (See Figure 62). • Modify the direction of the profile above the left side of POP Linein the same way. • ClickProfileDeleteto delete the profiles which have obvious error (See Figure 63). • Modify other parts of the addendum in the same way. • The final addendum is shown in Figure 64. 39

    40. XIII.Modify Profile of Addendum Select a profile Figure 58 Figure 59 The modified profile direction Figure 57 Figure 60 40

    41. XIII.Modify Profile of Addendum Figure 61 Figure 62 Figure 63 41

    42. XIII.Modify Profile of Addendum Figure 64 42

    43. XIV.Create Addendum Surface • ClickGenerate(See Figure 65). • Select POP Line, Profile Line and Addendum Surf in the displayed menu. Click Apply to generate addendum surface automatically (See Figure 66). • Click Closeto exit and save the database. Figure 65 After generating surface Before generating surface Figure 67 Figure 66 43

    44. XV.Binder Trim • ClickDFE Modification(See Figure 68). • SelectBINDER TRIM(See Figure 69). • Select binder type: Outer • Toggle offSurface. • SelectSelect(See Figure 70). • Select trim line (See Figure 71). • ClickOk to confirm. • ClickApply. • Click Yesto accept the displayed curve. • Click Closeto exit Binder Trim dialog box. • Click to show top view. • Close all the parts exceptC_BINDER(See Figure 72). • Click Close to exitMODIFICATIONdialog box. • Toggle onSurface. • Save the database. 44

    45. XV. Binder Trim Figure 68 Binder trim line Figure 70 Figure 69 Figure 72 Figure 71 45

    46. Die Face Design completed, setting up for the analysis

    47. Build a Blank • ClickParts. • Select Create • Type Blank in the Name.

    48. Mesh the Blank • 1. Click Blank Generator • 2. Select Create Line • 3. Select pick the corner location of the blank

    49. Mesh the Blank • 1. Click Boundary Line • 2. Select the blank outline • 3. Enter 20 for blank element size

    50. Mesh the Blank Blank Mesh Click Yes to accept the mesh