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5 AutoForm–Trim
AutoForm–Trim is a module to determine either a blank outline or a cut contour outline in connection with the AutoForm–Incremental solver so that the part reaches the defined target boundary at the end of the forming process. Use AutoForm–Trim for the following typical cases: • Calculation of the customized blank sheet for crash forming parts • Calculation of the customized blank sheet for a predefined target boundary of a drawing part • Calculation of the final cut contour in areas in which additional forming steps follow (e.g. second forming, bending operation, flanging operation) Pre–condition for the calculation of the blank outline and the cut contour is a simulation with AutoForm–Incremental containing all necessary forming and cutting operations. Basing on this simulation you define parameters for the calculation of the blank outline and the cut contour. The parameters for the calculation of a blank outline are the target boundary of the part and the forming process after which the target boundary has to be reached. Subsequently the outline of the initial blank is modified iteratively by the simulation of all necessary forming operations until the part has reached the target boundary at the end of the forming process. For the calculation of a cut contour with AutoForm–Trim you need the 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 iteratively by 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 contours, no hole contours or inner cut contours. The accuracy of the calculation of the blank outline and the cut contour depends on the chordal deviation of the FEA model for the tools and the part.
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Contents of the Workshop „AutoForm–Trim“ Lesson1
Blank outline optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lesson 2
Optimization of a trimming cut outline . . . . . . . . . . . . . . . . . . 11
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Lesson 1: Blank outline optimization
5. 1 Lesson 1: Blank outline optimization The following example shows how to use AutoForm–Trim 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 blank outline to optimize • tr_lesson_01_target.igs: The final outline
The simulation Open the sim file tr_lesson_01_basis.sim File > Open ... > Select a file > Files: tr_lesson_01_basis.sim > OK Fig. 1.1
The initial geometry
Trim calculation Open the Input generator and create Trim: Input generator > Create > Trim
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Lesson 1: Blank outline optimization Fig. 1.2
Create Trim Then you’ve got a new page in the Input generator called Trim. Fig. 1.3
The Trim page in the Input generator On the Trim page, select the option Optimize blank outline: Trim
Optimization type > Optimize blank outline Target process step: Process step where you want to get the final part with the correct outline. Target process step: drawing which corresponds to the process step 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 target process step. www.forum.alghaform.com
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Lesson 1: Blank outline optimization Target boundary > Import > IGES > tr_lesson_01_target.igs > Curve 1 and Curve 2 > OK
Trim
(To select both Curve 1 and 2, first select curve 1 and then select curve 2 while pressing the Ctrl key) Max # of iterations: 5 We have to define the maximum number of iterations (maximum number of simulations) Max deviation: 1.2 We have to define the maximum deviation (mm) of the cutting contour from the target boundary. Fig. 1.4
Selection of the target outline
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Lesson 1: Blank outline optimization Fig. 1.5
The Trim 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. 1.6
Start trim In this example, you’ve got the correct result in just 2 iterations.
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Lesson 1: Blank outline optimization
Trim results management AutoForm saves in the trim file (tr_lesson_01_basis.trm) the informations concerning the different iterations it has made, and it creates 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 interface
File > Open trim ... > Select a file > Files: tr_lesson_01.trm
Fig. 1.7
The Trim manager manager; open simulation 2 You get access to the following functions: • Convergence … allows you to check the convergence for each 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 (generally the last one) and then export the optimized cut contour. In order to do so, open the curve manager, select the contour you want to export and export it. Model > Curve manager >Blank outline > File > Export...
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Lesson 1: Blank outline optimization Fig. 1.8
Export with the curve manager Fig. 1.9
Blank outline, target boundary and part at the beginning of the calculation of the blank outline with AutoForm–Trim
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Lesson 1: Blank outline optimization Fig. 1.10
Blank outline, target boundary and part after the calculation of the blank outline with AutoForm–Trim
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Lesson 2: Optimization of a trimming cut outline
5. 2 Lesson 2: Optimization of a trimming cut outline The following example shows how to use AutoForm–Trim in order to optimize a trimming cut contour. The following files are needed to run the example: • tr_lesson_02_basis.sim: The simulation with the cut outline to optimize • tr_lesson_02_target.af: The final outline
The Simulation Open the sim file tr_lesson_02_basis.sim: File > Open ... > Select a file > Files: tr_lesson_02_basis.sim Fig. 2.1
The initial geometry
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Lesson 2: Optimization of a trimming cut outline
Trim calculation Once the simulation is over, open the Input generator and create Trim: Input generator > Create > Trim Fig. 2.2
Create Trim Then you’ve got a new page in the Input generator called Trim. Fig. 2.3
The Trim page in the Input generator On the Trim page, select the option Optimize cut contour: Trim
Optimization 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 outline Cut process step > 2_cutting1 which corresponds to the trimming cut operation Target process step: Process step where you want to get the final part with the correct outline. Target process step > 4_abkanten which corresponds to the process step 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 target process step. Trim
Target 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 (maximum number of simulations). Max deviation: 1.2 We have to define the maximum deviation (mm) of the cutting contour from the target boundary.
Fig. 2.4
Selection of the target outline
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Lesson 2: Optimization of a trimming cut outline Fig. 2.5
The Trim 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. 2.6
Start trim In this example, you’ve got the correct result in just 2 iterations
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Lesson 2: Optimization of a trimming cut outline
Trim results management AutoForm saves in the first sim file (tr_lesson_02_basis.sim) the informations concerning the different iterations it has made, and it creates 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 interface
File > Open trim ... > Select a file > Files: tr_lesson_02.trm
Fig. 2.7
The Trim manager manager; open simulation 2 You get access to the following functions: • Convergence … allows you to check the convergence for each 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 (generally the last one) and then export the optimized cut contour. In order to do so, open the curve manager, select the contour you want to export and export it. User interface
Model > Curve manager > Cut contour 1 > File > Export... www.forum.alghaform.com
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Lesson 2: Optimization of a trimming cut outline Fig. 2.8
Export with the Curve manager
Miscellaneous informations concerning the correct use of the Trim modulus. Always remember to select the Write Restart option in the Control page of the Input generator for the basis simulation. The Trim modulus uses this restart file and you won’t be able to create a trim without it. Fig. 2.9
Blank outline, target boundary and part at the beginning of the calculation of the cut contour with AutoForm–Trim www.forum.alghaform.com
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Lesson 2: Optimization of a trimming cut outline Fig. 2.10
Blank outline, target boundary and part after of the calculation of the cut contour with AutoForm–Trim In order to be sure of the Trim computation, follow these advice: • It is better to give a realistic initial trimming cut contour or blank outline. • Try to make two calculations with two different initial cut contours and then compare the results you get with the two computations. If you get the same results, then you’ve got the correct result. • Generally, AutoForm–Trim gives the right result in less than 5 iterations.
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Lesson 2: Optimization of a trimming cut outline
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