Sheet metal transferring/handling using ETA/DYNAFORM

1. DYNAFORM 5.9.4 Training Tutorial

2. 2
Bodyside

3. 3
Sheet Metal Transferring/Handling Process
1) Open model
2) Open SMTH window
3) Define blank
4) Define tools
5) Position tools
6) Define cup motion
7) Preview cup motion
8) Define control parameters
9) Submit job
10)Post-process results

4. 4
Figure 1.1
Figure 1.2
I. Open model
1. Start eta/DYNAFORM 5.9.4.
2. Click FileOpen…
3. Select file: bodyside_smth.df
4. Select Open to open the model.
5. Click FileSave As…
6. Save file as bodyside_smth_name_date.df

5. 5
I. Open model
Figure 1.3

6. 1. Click DSASheet Metal Transferring/Handling.
6
Figure 1.4
Figure 1.5
II. Open SMTH window

7. 7
Figure 1.7
Figure 1.6
III. Define blank
1. In Blank page, click Define geometry… to define blank.
2. Click Add Part… in Define geometry dialog window.
3. Select BLANK in Select Part dialog window.
4. Click OK button to dismiss the dialog window.
5. Click Exit button to dismiss Define geometry dialog window.

8. 8
Figure 1.8
Figure 1.9
6. Click <None> button to display Material dialog window.
7. Click Material Library… to display Material Library window.
8. Select DDQIF.
9. Click Ok button.
10.Click OK button to dismiss Material dialog window.
11.Key in blank thickness: 0.8 (mm).
III. Define blank

9. 9
Figure 1.12
Figure 1.11
Figure 1.10
1. Click Tools tab.
2. Click Define geometry… to define cup.
3. Click Add Part… button in Define geometry dialog window.
4. Select Suction in Select Part dialog window.
5. Click OK button to dismiss the dialog window.
6. Click Exit button to dismiss Define geometry dialog window.
IV. Define tools

10. 10
Figure 1.15
Figure 1.14
Figure 1.13
IV. Define tools
7. Click Tool button.
8. Click Define geometry… button to display Define geometry dialog window.
9. Click Add Part… button.
10.Select PUNCH and BINDER listed in Select Part dialog window.
11.Click OK button to dismiss the dialog window.
12.Click Exit button to dismiss Define geometry dialog window.

11. 11
Figure 1.18
Figure 1.17
Figure 1.16
IV. Define tools
13.Click Add button.
14.Key in New Tool name: Guide.
15.Toggle on Use as guide pin option.
16.Click Apply button to complete the operation.
17.Repeat steps 8-12 to define GUIDE1 and GUIDE2 as guide tools.

12. 12
Figure 1.21
Figure 1.20
Figure 1.19
IV. Define tools
18.Click Add button.
19.Key in New Tool name: Dummy.
20.Toggle on Use as dummy cup option.
21.Click Apply button to complete the operation.
22.Repeat steps 8-12 to define DUMMY1, DUMMY2, SUC2, and SUC3 as dummy
tools.

13. 13
Figure 1.22
V. Position tools
1. Click cup button in Tools page.
2. Click AutoPosition Cup button to automatically position cups.

14. 14
Figure 1.24
Figure 1.23
VI. Define cup motion
1. Click Process tab.
2. Click Import button.
3. Select Schuler motion.csv from the displayed window.
4. Select Transfer along Y-axis as flow direction of cup.

15. 15
Figure 1.25
VI. Define cup motion
5. Click View button to review the motion curve of the cup.
6. Click OK button to dismiss Load Curve window.

16. 16
Figure 1.26
VII. Preview cup motion
1. Click Preview button display the Animate dialog window.
2. Click Play button to review cup motion
3. Click Stop button to cease animation and dismiss the Animate dialog window.
Figure 1.27

17. 17
Figure 1.28
VIII. Define control parameters
1. Click Control tab.
2. Key in Time Step Size (DT2MS): -4e-006.

18. 18
Figure 1.30
Figure 1.29
IX. Submit job
1. Click Submit Job button.
2. Key in No. of CPUs (ncpu): 1.
Note: Users may key in higher ncpu according to availability of LS-DYNA® license.
3. Click OK button to submit job.
4. The Job Submitter window is displayed.

19. 19
Figure 1.31
IX. Submit job

20. 20
X. Post-process results

21. 21
Hood

22. 22
Sheet Metal Transferring/Handling Process
I. Open model
II. Blank Mesh
III. Tool Mesh
IV. Open Sheet Metal Transferring/Handling
V. Define blank
VI. Define tools
VII. Define cup motion
VIII. Position Cup and Blank
IX. Preview Tool motion
X. Submit job

23. 23

24. 24
Figure 2.1 Figure 2.2
I. Open Model
1. Start eta/DYNAFORM5.9.4.
2. Click menu File/Open…
3. Select file: Big_hoods.df
4. Click Open to open the file.

25. Figure 2.3 Figure 2.4 25
II. Blank Mesh
1. Click PartsCurrent.
2. Select blank in the list and set it as the current part.
3. Click Ok to exit.
4. Click menu PartsTurn On.
5. Click All off and select blank in the list to open it.
6. Click Ok to exit.

26. Figure 2.5 Figure 2.6 Figure 2.7 26
II. Blank Mesh
6. Click UserSetupBlank Generator.
7. Click Add Part… button.
8. Select BLANK.
9. Click OK button.
10. Click Blank Mesh… button.
11. Key in Element Size: 50 (mm). Click OK following by clicking Exit button.

27. Figure 2.8 Figure 2.9 27
III. Tool Mesh
1. Click the menu PartsTurn On
2. Click All off and select punch in the list to
open it.
3. Click OK button to exit.
4. Select Tool mesh icon in the toolbar.
5. Toggle on In Original Part option.
6. Click Select Surface.
7. Select the Drag Window option as the
selection method (See Figure 2.9).
8. Select the surface in the graphical area.
9. Click OK button to exit.
10. Click Apply to mesh.
11. Repeat the above steps to mesh the
remaining tools.

28. 1. Click the menu DSASheet Metal Transferring/Handling
28
Figure 2.10
Figure 2.11
IV. Open Sheet Metal Transfer/Handling

29. 29
Figure 2.14
Figure 2.13
Figure 2.12
V. Define Blank
1. In Blank page, click Define geometry… button to define
blank.
2. Click Add Part… button in the Define geometry window.
3. Select BLANK in the Select Part window.
4. Click OK to dismiss the window.
5. Click Exit to dismiss Define geometry window.

30. 30
Figure 2.15
Figure 2.16
V. Define Blank
6. Click BLANKMAT to define material.
7. Click Material Library… and select DDQIF material.
8. Click Ok
9. Click OK to dismiss the Material window.
10.Key in blank thickness: 1.0 (mm)

31. 31
Figure 2.19
Figure 2.18
Figure 2.17
VI. Define Tool
1. Click Tool tab.
2. Click Define geometry… to define cup.
3. Click Add Part… button to display the Define geometry window.
4. Select Suction in the Select Part window.
5. Click OK to dismiss the window.
6. Click Exit to dismiss the Define geometry window.

32. 32
Figure 2.22
Figure 2.21
Figure 2.20
VI. Define Tool
7. Click Tool button.
8. Click Define geometry… button to define tool.
9. Click Add Part… button in Define geometry window.
10.Select Punch in the Select Part window.
11.Click OK to dismiss the window.
12.Click Exit to dismiss the Define geometry window.

33. 33
Figure 2.25
Figure 2.24
Figure 2.23
VI. Define Tool
13.Click Dummy button.
14.Click Define geometry… button to define dummy.
15.Click Add Part… button in Define geometry window.
16.Select Dummy 1 and 2, Suc 2 and Suc 3 in the Select Part window.
17.Click OK to dismiss the window.
18.Click Exit to dismiss the Define geometry window.

34. 34
Figure 2.28
Figure 2.27
Figure 2.26
VI. Define Tool
19.Click Binder button.
20.Click Define geometry… button to define dummy.
21.Click Add Part… button in Define geometry window.
22.Select Binder in the Select Part window.
23.Click OK to dismiss the window.
24.Click Exit to dismiss the Define geometry window.

35. 35
Figure 2.30
Figure 2.29
VII. Define Cup Motion
1. Click Process tab.
2. Click Import… button.
3. Select Hood-Schuler motion.csv file
4. Select Transfer along Y axis as the motion direction of cup.

36. 36
Figure 2.31
VII. Define Cup Motion
5. Click View button to view the motion curve of cup.
6. The program will automatically obtain the simulative motion curve according to the trace
curve.
7. The difference between the maximum and minimum values along the horizontal axis is
3850mm which is also the transferring distance of the cup.
8. The difference between the maximum and minimum values along the vertical axis is
480mm which is also the height for grabbing the blank.
9. The difference between the maximum value and the position to put down the blank along
the vertical axis is 227mm which is also the height for putting down the blank.
10. Click OK to dismiss the View window.

37. 37
Figure 2.32
VIII. Position Cup and blank
1. Click Tools tab.
2. Toggle on the option for repositioning cup and blank

38. 38
Figure 2.33
IX. Preview Tool Motion
1. Click Preview to preview motion of cup and blank.
2. Click Play button.
3. Click Stop button.
Figure 2.34

39. 39
Figure 2.35
X. Submit Job
1. Click Submit Job button.
2. Click OK button.
Figure 2.36

40. 40
Figure 2.37
X. Submit Job