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7/28/2019 AutoForm Trim
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7/28/2019 AutoForm Trim
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ALGHAFORM PAYLASIMIDIR
www.forum.alghaform.com
iletisim: [email protected]
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5555 AutoFormTrimAutoFormTrimAutoFormTrimAutoFormTrim
AutoFormTrim is a module to determine either a blank outline or acut contour outline in connection with the AutoFormIncrementalsolver so that the part reaches the defined target boundary at theend of the forming process. Use AutoFormTrim for the followingtypical cases:
Calculation of the customized blank sheet for crash form-ing parts
Calculation of the customized blank sheet for a predefinedtarget boundary of a drawing part Calculation of the final cut contour in areas in which addi-
tional forming steps follow (e.g. second forming, bendingoperation, flanging operation)
Precondition for the calculation of the blank outline and the cutcontour is a simulation with AutoFormIncremental containing allnecessary forming and cutting operations. Basing on this simulationyou define parameters for the calculation of the blank outline and
the cut contour.
The parameters for the calculation of a blank outline are the targetboundary of the part and the forming process after which the targetboundary has to be reached. Subsequently the outline of the initialblank is modified iteratively by the simulation of all necessaryforming operations until the part has reached the target boundaryat the end of the forming process.
For the calculation of a cut contour with AutoFormTrim you needthe following input:
Cut contour to be optimized Target boundary for the part Forming process after which the target boundary has been
reached
Subsequently the contour of the defined cut is modified iterativelyby the simulation of all necessary forming operations until the part
has reached the target boundary at the end of the forming process.
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With the current version 3.1 you can only calculate outer cut con-tours, no hole contours or inner cut contours.
The accuracy of the calculation of the blank outline and the cut con-tour depends on the chordal deviation of the FEA model for the
tools and the part.
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Contents of the Workshop AutoFormTrimContents of the Workshop AutoFormTrimContents of the Workshop AutoFormTrimContents of the Workshop AutoFormTrim
Lesson1Lesson1Lesson1Lesson1 Blank outline optimizationBlank outline optimizationBlank outline optimizationBlank outline optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .4444
Lesson 2Lesson 2Lesson 2Lesson 2 Optimization of a trimming cut outlineOptimization of a trimming cut outlineOptimization of a trimming cut outlineOptimization of a trimming cut outline . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 11111111
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Lesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimization
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5. 15. 15. 15. 1 Lesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimization
The following example shows how to use AutoFormTrim in order to optimize a blank
outline.
The following files are needed to run the example:
tr_lesson_01_basis.sim: The simulation with the blankoutline to optimize
tr_lesson_01_target.igs: The final outline
The simulationThe simulationThe simulationThe simulationOpen the sim file tr_lesson_01_basis.sim
File > Open ... > Select a file > Files: tr_lesson_01_basis.sim > OK
Fig. 1.1Fig. 1.1Fig. 1.1Fig. 1.1
The initial geometry
Trim calculationTrim calculationTrim calculationTrim calculationOpen the Input generator and create Trim:
Input generator > Create > Trim
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Lesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimization
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Fig. 1.2Fig. 1.2Fig. 1.2Fig. 1.2
Create TrimTrimTrimTrim
Then youve got a new page in the Input generator called Trim.
Fig. 1.3Fig. 1.3Fig. 1.3Fig. 1.3
The TrimTrimTrimTrim page in the Input generator
On the Trim page, select the option Optimize blank outline:
TrimTrimTrimTrim Optimization type > Optimize blank outline
Target process step: Process step where you want to get the finalpart with the correct outline.
Target process step: drawing which corresponds to the process stepwhere we want to get the correct outline at the end of the step.
Target Boundary: To give the correct target outline.
We must give the final outline we want to get at the end of the tar-get process step.
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Lesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimization
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TrimTrimTrimTrimTarget boundary > Import > IGES > tr_lesson_01_target.igs >Curve 1 and Curve 2 > OK
(To select both Curve 1 and 2, first select curve 1 and then selectcurve 2 while pressing the Ctrl key)
Max # of iterations:5
We have to define the maximum number of iterations (maximumnumber of simulations)
Max deviation:1.2
We have to define the maximum deviation (mm) of the cutting con-
tour from the target boundary.
Fig. 1.4Fig. 1.4Fig. 1.4Fig. 1.4
Selection of the target outline
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Lesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimization
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Fig. 1.5Fig. 1.5Fig. 1.5Fig. 1.5
The TrimTrimTrimTrim page at the end of the input
Now you can launch the Trim calculation:
File > Save as > tr_lesson_01.trm
Job > Start trim > Save > Start
Fig. 1.6Fig. 1.6Fig. 1.6Fig. 1.6
Start trimStart trimStart trimStart trim
In this example, youve got the correct result in just 2 iterations.
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Lesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimization
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Trim results managementTrim results managementTrim results managementTrim results managementAutoForm saves in the trim file (tr_lesson_01_basis.trm) the infor-mations concerning the different iterations it has made, and it cre-ates files for each iteration of the Trim modulus(tr_lesson_01_basis_trm1.sim, tr_lesson_01_basis_trm2.sim etc.).
Open the file tr_lesson_01_basis.trm to open the Trim manager:
User interfaceUser interfaceUser interfaceUser interfaceFile > Open trim ... > Select a file > Files:tr_lesson_01.trm
Fig. 1.7Fig. 1.7Fig. 1.7Fig. 1.7
The Trim managerTrim managerTrim managerTrim manager; open simulation 2222
You get access to the following functions:
Convergence allows you to check the convergence foreach simulation and then choose the best one. Open allows you to choose which simulation you want to
open, the basis simulation or one of the trim simulation.
Then you can choose the simulation you want to open (generallythe last one) and then export the optimized cut contour.
In order to do so, open the curve manager, select the contour youwant to export and export it.
User interfaceUser interfaceUser interfaceUser interfaceModel > Curve manager >Blank outline > File > Export...
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Lesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimization
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Fig. 1.8Fig. 1.8Fig. 1.8Fig. 1.8
Export with the curve manager
Fig. 1.9Fig. 1.9Fig. 1.9Fig. 1.9
Blank outline, target boundary and part at the beginning of the cal-
culation of the blank outline with AutoFormTrim
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Lesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimization
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Fig. 1.10Fig. 1.10Fig. 1.10Fig. 1.10
Blank outline, target boundary and part after the calculation of the
blank outline with AutoFormTrim
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Lesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outline
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5. 25. 25. 25. 2 Lesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outline
The following example shows how to use AutoFormTrim in order to optimize a trim-
ming cut contour.
The following files are needed to run the example:
tr_lesson_02_basis.sim: The simulation with the cut out-line to optimize
tr_lesson_02_target.af: The final outline
The SimulationThe SimulationThe SimulationThe SimulationOpen the sim file tr_lesson_02_basis.sim:
File > Open ... > Select a file > Files: tr_lesson_02_basis.sim
Fig. 2.1Fig. 2.1Fig. 2.1Fig. 2.1
The initial geometry
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Lesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outline
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Trim calculationTrim calculationTrim calculationTrim calculationOnce the simulation is over, open the Input generator and createTrim:
Input generator > Create > Trim
Fig. 2.2Fig. 2.2Fig. 2.2Fig. 2.2
Create TrimTrimTrimTrim
Then youve got a new page in the Input generator called Trim.
Fig. 2.3Fig. 2.3Fig. 2.3Fig. 2.3
The TrimTrimTrimTrim page in the Input generator
On the Trim page, select the option Optimize cut contour:
TrimTrimTrimTrimOptimization type > Optimize cut contour
Cut process step: to define the cutting process step where you want
to optimize the cut contour.
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Lesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outline
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Cut process step > 2_cutting1 which corresponds to the trimmingcut operation
Target process step: Process step where you want to get the finalpart with the correct outline.
Target process step > 4_abkanten which corresponds to the processstep where we want to get the correct outline at the end of the step.
Target Boundary: To give the correct target outline.
We must give the final outline we want to get at the end of the tar-get process step.
TrimTrimTrimTrimTarget boundary > Import > af > Keep orientation >tr_lesson_02_target.af > Curve 4 > OK
Max # of iterations: 5
We have to define the maximum number of iterations (maximumnumber of simulations).
Max deviation: 1.2
We have to define the maximum deviation (mm) of the cutting con-tour from the target boundary.
Fig. 2.4Fig. 2.4Fig. 2.4Fig. 2.4
Selection of the target outline
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Fig. 2.5Fig. 2.5Fig. 2.5Fig. 2.5
The TrimTrimTrimTrim page at the end of the input
Now you can launch the Trim calculation:
File > Save as > tr_lesson_02.trm
Job > Start trim > Save > Start
Fig. 2.6Fig. 2.6Fig. 2.6Fig. 2.6
Start trimStart trimStart trimStart trim
In this example, youve got the correct result in just 2 iterations
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Lesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outline
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Trim results managementTrim results managementTrim results managementTrim results managementAutoForm saves in the first sim file (tr_lesson_02_basis.sim) theinformations concerning the different iterations it has made, and itcreates files for each iteration of the Trim modulus(tr_lesson_02_basis_trm1.sim, tr_lesson_02_basis_trm2.sim etc.).
Open the tr_lesson_02_basis.trm file to open the Trim manager:
User interfaceUser interfaceUser interfaceUser interface File > Open trim ... > Select a file > Files: tr_lesson_02.trm
Fig. 2.7Fig. 2.7Fig. 2.7Fig. 2.7
The Trim managerTrim managerTrim managerTrim manager; open simulation 2222
You get access to the following functions:
Convergence allows you to check the convergence foreach simulation and then choose the best one. Open allows you to choose which simulation you want to
open, the basis simulation or one of the trim simulation.
Then you can choose the simulation you want to open (generallythe last one) and then export the optimized cut contour.
In order to do so, open the curve manager, select the contour youwant to export and export it.
User interfaceUser interfaceUser interfaceUser interface Model > Curve manager > Cut contour 1 > File >Export...
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Lesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outline
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Fig. 2.8Fig. 2.8Fig. 2.8Fig. 2.8
Export with the Curve manager
Miscellaneous informations concerning the correctMiscellaneous informations concerning the correctMiscellaneous informations concerning the correctMiscellaneous informations concerning the correctuse of the Trim modulus.use of the Trim modulus.use of the Trim modulus.use of the Trim modulus.
Always remember to select the Write Restart option in the Controlpage of the Input generator for the basis simulation. The Trim mod-ulus uses this restart file and you wont be able to create a trimwithout it.
Fig. 2.9Fig. 2.9Fig. 2.9Fig. 2.9
Blank outline, target boundary and part at the beginning of the cal-culation of the cut contour with AutoFormTrim
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Lesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outline
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Fig. 2.10Fig. 2.10Fig. 2.10Fig. 2.10
Blank outline, target boundary and part after of the calculation of
the cut contour with AutoFormTrim
In order to be sure of the Trim computation, follow these advice:
It is better to give a realistic initial trimming cut contour orblank outline.
Try to make two calculations with two different initial cut
contours and then compare the results you get with thetwo computations. If you get the same results, then youvegot the correct result.
Generally, AutoFormTrim gives the right result in lessthan 5 iterations.
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Lesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outline
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