Manufacturing Solutions
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Manufacturing Solutions
HF0150: Quick Setup
This tutorial describes the steps required for modeling and running one step analysis that can be performed in HyperForm within the RADIOSS
One Step user profile.
The following steps are involved in one step analysis:
1.
Geometry cleanup and meshing
2.
Assigning materials and thickness
3.
Defining symmetry
4.
Defining blankholders
5.
Defining drawbeads
6.
Setting the stamping direction either by tipping the part or by using the existing part orientation as the forming axis
7.
Checking for undercuts
8.
Running the analysis
Exercise 1: Geometry Cleanup and Meshing
This exercise uses the model file Part1a.igs. The following image shows the program with the RADIOSS One Step user profile and model file
loaded:
Step 1: Load the model file
1.
Click File > Import....
2.
Click the Import Geometry icon
3.
Click the Select Files icon
4.
Click Import and then click Close.
.
and browse to the file <installation_directory>\tutorials\mfs\hf\1Step\part1a.igs.
Step 2: Geometry cleanup
1.
In the OneStep tab, rightclick on Parts > New > Pick... as shown in the image below:
Note: The component name is recognized automatically as Part once the model is loaded into the session.
2.
Pick the part from the screen.
3.
Click on proceed.
Note: The material CRDQ steel and a thickness of 1 mm is assigned to the part by default.
4.
Rightclick on the part lvl1 and select Geometry > Remove Holes.
5.
In the diameter< field, enter 40.
6.
Click on the yellow surfs button to highlight it. Click again and select displayed from the extended entity selection menu. This selects all
the entities on the screen.
7.
Click find. All pinholes found are highlighted with xP.
8.
Click delete to close the hole.
9.
Click return to close the panel.
Step 3: Meshing the part
1.
Rightclick on the part lvl1 and select Mesh > RMesh.
2.
Enter the values as shown below:
3.
Click on Mesh....
4.
Click surfs and select displayed from the extended entity selection menu. This selects all the surfaces displayed on the screen.
5.
Click proceed.
6.
Click Close.
Exercise 2: Setting up One Step Analysis
Step 1: Assigning the material and thickness to the part
1.
Rightclick on CRDQ Steel > Database... to change the material selection.
Note: A userdefined material can also be added to the database by editing the material file hf.dat.
2.
When finished viewing/changing the material selection, click Close to close the dialog.
3.
Highlight Thickness:1 by clicking on it once. Doubleclick on the digit 1 to make it editable and change the value to 1.5.
Step 2: Setting symmetry conditions
1.
In the OneStep tab, rightclick on Symmetry:No > Edit.
2.
Click on the yellow nodes button and select on plane from the extended entity selection menu.
3.
Click the toggle switch to x axis.
4.
Pick a point on the symmetric plane, as shown below.
5.
Click select entities.
6.
Under Constraint Type, click the X radio button.
7.
Click size = and enter 10.
8.
Click update.
9.
Click return.
constraints along the symmetric edge
Step 3: Setting the stamping direction
1.
Right click on Stamping Direction:X and select Z.
Note: Stamping can also be done in any of the three principal axes or an arbitrary axis in space by using Stamping Direction in the
Autotip panel. Use the stamping direction subpanel to specify the stamping in an arbitrary direction.
–
In the Autotip panel, use the vector selector switch to assign a direction. If the stamping direction of the part is not one of the
principal axes, use N1, N2, N3 option and select 2 nodes on the model to define a direction.
–
Click set.
Step 4: Selecting the blankholder
Blankholders can be defined as the upper and lower holding surfaces that control metal flow around a shape to be formed in a draw operation.
They supply a restraining force on the material during the pressing process.
HyperForm allows you to define the blankholder force in two ways: on element and on edge. The correlation between the magnitude and level of
the applied forces is always available. Edge blankholder force application allows you to restrain an edge by enabling automatic selection of all
nodes between two userdefined nodes along a free edge of a part.
You can define the blankholder force in two ways: tonnage force or pressure level (high, medium and low).
Note:
The pressure level is proportional to the area of blank under the blankholder as well as thickness. A pressure level of 2MPa, 5MPa and
10MPa for a 1mm blank has been chosen as a reference for Low, Medium, and High (based on practical experience). The tonnage
(metric ton unit) is equivalent to the pressure times the blankholder area normalized/scaled by the thickness (1 metric ton = 9810N).
1.
In the OneStep tab, right click on Blankholders > New. If desired, you can double click on Blankholder1 to change the name.
2.
Right click on Blankholder1 > Elements…
3.
Click elems and select on plane.
4.
Select zaxis and pick a node on the binder (flat region) for B (base node).
5.
Click proceed.
6.
Friction, Tonnage and Pressure level appears below Blankholder1. Double click on the values for Friction and Tonnage to change the
values.
7.
Right click on Pressure Level: and select Medium.
Notice that the Tonnage changes according to the selected pressure level.
Step 5: Creating drawbeads
Modeling the exact drawbead geometry requires a large number of elements, which increases CPU time dramatically. A practical approach is to
use an equivalent drawbead model by representing the drawbead analytically and providing a constant drawbead restraining force and closure
force.
Use the calculate subpanel to determine the closure and restraining force based on drawbead dimensions. The restraining force is the value of
the force (per unit length) applied by the bead in the plane of the blank surface. The closure force is the force (per unit length) required in the
perpendicular direction to keep the drawbead closed.
1.
From the OneStep tab, rightclick on Drawbeads > New > Restrain….
2.
Pick two nodes on the part as indicated in the image below to define the drawbeads.
3.
Click Proceed.
Notice a message shows "The drawbead set has been created." A line representing drawbeads is created.
4.
Notice that Drawbead1 is created with a default Restraint Force and Pressure Level. Double click Drawbead1 to rename it.
5.
Right click on Pressure Level > Medium. Notice that Restraint Force changes based on the Pressure Level selection.
Step 6: Tipping
1.
Right click on the OneStep tab anywhere in the red box as shown below and select Autotip.
2.
Select the autotip radio button.
3.
Verify the entity selector is set to comps and select the lvl1 component.
4.
Verify the toggle is set to full model and keep the rest of the options as default.
5.
Click calc autotip.
Notice the angle to be tilted is displayed on the header bar on the left hand bottom corner and the magnitude is displayed in the angle field.
6.
Click autotip.
This action will tilt the part by an angle calculated by HyperForm to reduce draw depth during forming.
7.
Click return.
Step 7: Checking for undercuts
1.
Right click on the OneStep tab anywhere in the red box as shown above and select Undercut Check.
2.
Click on the yellow comps button to highlight it.
3.
Pick the part from the screen.
4.
Click on check undercut.
Notice the message “0 elements with undercut detected”. If there are undercuts in the model then the failed elements are highlighted on the
screen.
5.
Click return.
Step 8: Checking the model and running the analysis
1.
Right click on the OneStep tab anywhere in the red box as shown above and select Check Model. A message is displayed on the message
bar, stating “Model checked.”
2.
Right click on the OneStep tab and select Run.
3.
Enter a name for the run.
The feasibility solver launches, as shown below:
Note: It is advised to run the analysis into a separate folder.
Exercise 3: Post processing
After the successful completion of the run, right click on the white space of the OneStep tab to see the Blank Shape, %thinning and
Formability options, which were not available before running the analysis.
Right click and select the desired result type for post processing.
Step 1: Blank Shape
1.
Right click on the OneStep tab anywhere in the white space and select Blank Shape.
2.
Under Blank Shape Profile: click on the Initial radio button. Notice that the initial blank shape is displayed on the screen, as shown
below.
3.
Click on export to write out an iges boundary of the predicted blank shape to the folder where feasibility analysis was run. The file will be
named as <filename>_blank.iges.
Exercise 4: Blank Fit
Step 1: Fitting the initial blank shape into different configurations
1.
From the Tools menu, click on Blank Fit. This will bring up the blank fit utility, as shown below:
2.
Use the Part drop down menu to select the component on which the one step analysis was run.
3.
Keep the default values for Density and Cost per Kg.
4.
Under PLOT OPTIONS, click on the checkbox next to %Thinning and Formability. Notice that %Thinning and Formability buttons
becomes active.
5.
Rotate the model to a desired direction and click on %Thinning. This contours the model with %Thinning result type.
6.
Left click to capture the image to include it in the report. A right click will abort the function and return to the Blank Fit macro. This is
indicated by the image on the right hand bottom corner of the graphics area
7.
Under BLANK SHAPES, check all the boxes.
8.
Click on Blank Fit.
This will fit the blank into the selected shapes.
9.
Click on Publish Report.
.
This will open a HTML report with hyperlinks to blank shapes and results, as shown below.
11.
Click Close.
Exercise 5: Blank Nest
Step 1: Nesting the initial blank shape on coil or sheet
1.
Click Tools > Blank Nesting.
2.
Click on elems and select displayed from the extended entity selector menu.
3.
Click on the nesting button. A new window called Blank Nesting opens which allows you to nest the blank in different configurations.
4.
Right click any where on the blank shape and select Duplicate. This will create a duplicate of the existing blank shape.
5.
Right click anywhere on the blue screen and select Auto nesting from the menu. This will make the best fit of the 2 shapes of the blank on
a sheet.
6.
Click on File > Export.
7.
Enter a name and click on Save. This saves an .iges boundary of the nested sheet.
8.
Select File > Exit to close Blank Nesting.
Note: There is a detailed explanation of all the options in Blank Nesting in the HyperForm online help.
Exercise 6: Report Generation
Step 1: Publishing a report of the feasibility analysis results
1.
Click Tools > Report Generator. The Report Generator opens up as shown below:
2.
Click on the Result File: file browser icon and select <filename>.res in the folder where you have run the feasibility analysis.
Note: You must run feasibility analysis in a separate folder with no spaces in the path and in the folder name.
3.
Click on the Report Name: file browser icon and type a name for the report.
Note: The folder and report name must not have any spaces in the folder name or file name.
4.
Check all the boxes under Result Types.
5.
Under Export Mode, select HTML.
6.
Under Export Options, select JPEG.
7.
Click on Generate. This creates a report in the folder selected in the Report Name field. It includes folders called <filename>_data_dir
and <filename>.hml.
8.
Open the folder that was selected for Report Name. Open the file <filename>.html in Internet Explorer or Firefox. This opens a html
page with hyperlinks to the selected result types and the corresponding image with contour, as shown below:
9.
Click Close to close the panel.
Return to RADIOSS One Step Tutorials
HF0150: Quick Setup
This tutorial describes the steps required for modeling and running one step analysis that can be performed in HyperForm within the RADIOSS
One Step user profile.
The following steps are involved in one step analysis:
1.
Geometry cleanup and meshing
2.
Assigning materials and thickness
3.
Defining symmetry
4.
Defining blankholders
5.
Defining drawbeads
6.
Setting the stamping direction either by tipping the part or by using the existing part orientation as the forming axis
7.
Checking for undercuts
8.
Running the analysis
Exercise 1: Geometry Cleanup and Meshing
This exercise uses the model file Part1a.igs. The following image shows the program with the RADIOSS One Step user profile and model file
loaded:
Step 1: Load the model file
1.
Click File > Import....
2.
Click the Import Geometry icon
3.
Click the Select Files icon
4.
Click Import and then click Close.
.
and browse to the file <installation_directory>\tutorials\mfs\hf\1Step\part1a.igs.
Step 2: Geometry cleanup
1.
In the OneStep tab, rightclick on Parts > New > Pick... as shown in the image below:
Note: The component name is recognized automatically as Part once the model is loaded into the session.
2.
Pick the part from the screen.
3.
Click on proceed.
Note: The material CRDQ steel and a thickness of 1 mm is assigned to the part by default.
4.
Rightclick on the part lvl1 and select Geometry > Remove Holes.
5.
In the diameter< field, enter 40.
6.
Click on the yellow surfs button to highlight it. Click again and select displayed from the extended entity selection menu. This selects all
the entities on the screen.
7.
Click find. All pinholes found are highlighted with xP.
8.
Click delete to close the hole.
9.
Click return to close the panel.
Step 3: Meshing the part
1.
Rightclick on the part lvl1 and select Mesh > RMesh.
2.
Enter the values as shown below:
3.
Click on Mesh....
4.
Click surfs and select displayed from the extended entity selection menu. This selects all the surfaces displayed on the screen.
5.
Click proceed.
6.
Click Close.
Exercise 2: Setting up One Step Analysis
Step 1: Assigning the material and thickness to the part
1.
Rightclick on CRDQ Steel > Database... to change the material selection.
Note: A userdefined material can also be added to the database by editing the material file hf.dat.
2.
When finished viewing/changing the material selection, click Close to close the dialog.
3.
Highlight Thickness:1 by clicking on it once. Doubleclick on the digit 1 to make it editable and change the value to 1.5.
Step 2: Setting symmetry conditions
1.
In the OneStep tab, rightclick on Symmetry:No > Edit.
2.
Click on the yellow nodes button and select on plane from the extended entity selection menu.
3.
Click the toggle switch to x axis.
4.
Pick a point on the symmetric plane, as shown below.
5.
Click select entities.
6.
Under Constraint Type, click the X radio button.
7.
Click size = and enter 10.
8.
Click update.
9.
Click return.
constraints along the symmetric edge
Step 3: Setting the stamping direction
1.
Right click on Stamping Direction:X and select Z.
Note: Stamping can also be done in any of the three principal axes or an arbitrary axis in space by using Stamping Direction in the
Autotip panel. Use the stamping direction subpanel to specify the stamping in an arbitrary direction.
–
In the Autotip panel, use the vector selector switch to assign a direction. If the stamping direction of the part is not one of the
principal axes, use N1, N2, N3 option and select 2 nodes on the model to define a direction.
–
Click set.
Step 4: Selecting the blankholder
Blankholders can be defined as the upper and lower holding surfaces that control metal flow around a shape to be formed in a draw operation.
They supply a restraining force on the material during the pressing process.
HyperForm allows you to define the blankholder force in two ways: on element and on edge. The correlation between the magnitude and level of
the applied forces is always available. Edge blankholder force application allows you to restrain an edge by enabling automatic selection of all
nodes between two userdefined nodes along a free edge of a part.
You can define the blankholder force in two ways: tonnage force or pressure level (high, medium and low).
Note:
The pressure level is proportional to the area of blank under the blankholder as well as thickness. A pressure level of 2MPa, 5MPa and
10MPa for a 1mm blank has been chosen as a reference for Low, Medium, and High (based on practical experience). The tonnage
(metric ton unit) is equivalent to the pressure times the blankholder area normalized/scaled by the thickness (1 metric ton = 9810N).
1.
In the OneStep tab, right click on Blankholders > New. If desired, you can double click on Blankholder1 to change the name.
2.
Right click on Blankholder1 > Elements…
3.
Click elems and select on plane.
4.
Select zaxis and pick a node on the binder (flat region) for B (base node).
5.
Click proceed.
6.
Friction, Tonnage and Pressure level appears below Blankholder1. Double click on the values for Friction and Tonnage to change the
values.
7.
Right click on Pressure Level: and select Medium.
Notice that the Tonnage changes according to the selected pressure level.
Step 5: Creating drawbeads
Modeling the exact drawbead geometry requires a large number of elements, which increases CPU time dramatically. A practical approach is to
use an equivalent drawbead model by representing the drawbead analytically and providing a constant drawbead restraining force and closure
force.
Use the calculate subpanel to determine the closure and restraining force based on drawbead dimensions. The restraining force is the value of
the force (per unit length) applied by the bead in the plane of the blank surface. The closure force is the force (per unit length) required in the
perpendicular direction to keep the drawbead closed.
1.
From the OneStep tab, rightclick on Drawbeads > New > Restrain….
2.
Pick two nodes on the part as indicated in the image below to define the drawbeads.
3.
Click Proceed.
Notice a message shows "The drawbead set has been created." A line representing drawbeads is created.
4.
Notice that Drawbead1 is created with a default Restraint Force and Pressure Level. Double click Drawbead1 to rename it.
5.
Right click on Pressure Level > Medium. Notice that Restraint Force changes based on the Pressure Level selection.
Step 6: Tipping
1.
Right click on the OneStep tab anywhere in the red box as shown below and select Autotip.
2.
Select the autotip radio button.
3.
Verify the entity selector is set to comps and select the lvl1 component.
4.
Verify the toggle is set to full model and keep the rest of the options as default.
5.
Click calc autotip.
Notice the angle to be tilted is displayed on the header bar on the left hand bottom corner and the magnitude is displayed in the angle field.
6.
Click autotip.
This action will tilt the part by an angle calculated by HyperForm to reduce draw depth during forming.
7.
Click return.
Step 7: Checking for undercuts
1.
Right click on the OneStep tab anywhere in the red box as shown above and select Undercut Check.
2.
Click on the yellow comps button to highlight it.
3.
Pick the part from the screen.
4.
Click on check undercut.
Notice the message “0 elements with undercut detected”. If there are undercuts in the model then the failed elements are highlighted on the
screen.
5.
Click return.
Step 8: Checking the model and running the analysis
1.
Right click on the OneStep tab anywhere in the red box as shown above and select Check Model. A message is displayed on the message
bar, stating “Model checked.”
2.
Right click on the OneStep tab and select Run.
3.
Enter a name for the run.
The feasibility solver launches, as shown below:
Note: It is advised to run the analysis into a separate folder.
Exercise 3: Post processing
After the successful completion of the run, right click on the white space of the OneStep tab to see the Blank Shape, %thinning and
Formability options, which were not available before running the analysis.
Right click and select the desired result type for post processing.
Step 1: Blank Shape
1.
Right click on the OneStep tab anywhere in the white space and select Blank Shape.
2.
Under Blank Shape Profile: click on the Initial radio button. Notice that the initial blank shape is displayed on the screen, as shown
below.
3.
Click on export to write out an iges boundary of the predicted blank shape to the folder where feasibility analysis was run. The file will be
named as <filename>_blank.iges.
Exercise 4: Blank Fit
Step 1: Fitting the initial blank shape into different configurations
1.
From the Tools menu, click on Blank Fit. This will bring up the blank fit utility, as shown below:
2.
Use the Part drop down menu to select the component on which the one step analysis was run.
3.
Keep the default values for Density and Cost per Kg.
4.
Under PLOT OPTIONS, click on the checkbox next to %Thinning and Formability. Notice that %Thinning and Formability buttons
becomes active.
5.
Rotate the model to a desired direction and click on %Thinning. This contours the model with %Thinning result type.
6.
Left click to capture the image to include it in the report. A right click will abort the function and return to the Blank Fit macro. This is
indicated by the image on the right hand bottom corner of the graphics area
7.
Under BLANK SHAPES, check all the boxes.
8.
Click on Blank Fit.
This will fit the blank into the selected shapes.
9.
Click on Publish Report.
.
This will open a HTML report with hyperlinks to blank shapes and results, as shown below.
11.
Click Close.
Exercise 5: Blank Nest
Step 1: Nesting the initial blank shape on coil or sheet
1.
Click Tools > Blank Nesting.
2.
Click on elems and select displayed from the extended entity selector menu.
3.
Click on the nesting button. A new window called Blank Nesting opens which allows you to nest the blank in different configurations.
4.
Right click any where on the blank shape and select Duplicate. This will create a duplicate of the existing blank shape.
5.
Right click anywhere on the blue screen and select Auto nesting from the menu. This will make the best fit of the 2 shapes of the blank on
a sheet.
6.
Click on File > Export.
7.
Enter a name and click on Save. This saves an .iges boundary of the nested sheet.
8.
Select File > Exit to close Blank Nesting.
Note: There is a detailed explanation of all the options in Blank Nesting in the HyperForm online help.
Exercise 6: Report Generation
Step 1: Publishing a report of the feasibility analysis results
1.
Click Tools > Report Generator. The Report Generator opens up as shown below:
2.
Click on the Result File: file browser icon and select <filename>.res in the folder where you have run the feasibility analysis.
Note: You must run feasibility analysis in a separate folder with no spaces in the path and in the folder name.
3.
Click on the Report Name: file browser icon and type a name for the report.
Note: The folder and report name must not have any spaces in the folder name or file name.
4.
Check all the boxes under Result Types.
5.
Under Export Mode, select HTML.
6.
Under Export Options, select JPEG.
7.
Click on Generate. This creates a report in the folder selected in the Report Name field. It includes folders called <filename>_data_dir
and <filename>.hml.
8.
Open the folder that was selected for Report Name. Open the file <filename>.html in Internet Explorer or Firefox. This opens a html
page with hyperlinks to the selected result types and the corresponding image with contour, as shown below:
9.
Click Close to close the panel.
Return to RADIOSS One Step Tutorials
