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AutoForm Hydro
AutoForm Hydro
com
ALGHAFORM PAYLASIMIDIR
iletisim: omarer25@hotmail.com
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6 AutoFormHydro
Prebending
Annealing
Preforming (closing of tools without fluid medium)
Hydroforming (Forming with fluid medium)
In the current version, version 3.1, prebending is simulated in a single time step. This is a stable and efficient way to simulate prebending whereby changes in thickness and material hardening arising
from prebending may be computed. However, change in cross sectional shape during prebending cannot be established using this
singlestep approach.
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Lesson 2
Lesson 3
Lesson 4
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Import of a CADgeometry
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AutoFormUser Interface
Creating a new simulation file
User interface
File > New ... > New file > File name: hy_lesson_01 > OK
Fig. 1.3
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Fig. 1.5
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Faces:
Layers:
Geometry generator
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User interface
Fig. 1.8
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Fig. 1.12
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Tools
Tools
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Fig. 1.19
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Cross section > Circle ... > Cross section - Circle > Outer diameter:
58 > OK
Note:
Note Always the socalled neutral fiber has to be defined for the
cross section, except the definition of the cross section by Circle.
Circle In
this case the outer diameter will be automatically converted to the
neutral fiber.
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Tube
After the inputs for the tube are finished the page tube should
appear as shown in Fig. 1.22.
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Process
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Process
The subpage for this process step should look like shown below:
Fig. 1.29
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hydroforming > Tool control > Show all > upper_die > Control
mode: Stationary > lower_die > Control mode: Stationary
Inputs for the process of pressure must be specified in the field
Hydroforming. Clicking on the button No pressure starts up the
dialog box Pressure (Fig. 1.31).
Fig. 1.31
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Fig 1.32
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Fig. 1.34
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Analysis of results
In the following the analysis of the most important result variables
will be discussed.
Open the *.sim file after the solver finished the calculation.
User interface
User interface
Fig. 1.35
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Fig. 1.37
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Fig. 1.38
User interface
or
Select icon Thinning.
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Display of the result variable Thinning with min and max values in
the main display
Note:
Note The labels for max and min cannot be removed with the key
Esc.
Esc They have to be switched off by using Results > Show max and
Results > Show min as toggle switches.
To analyze the areas with high values for thinning the range of the
Thinning scale must be changed.
Results > Ranges ...
User interface
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Display of the result value Thinning with min value 0.4 and max
value 0.2.
0.2
Contact distance above
With this result variable the distance of each element to the surfaces
of the tools is displayed. Thus it is possible to check if the tube is
formed out at the end of the simulation, i.e. if it has contact to the
tool everywhere.
If this is not the case, the pressure must be increased or the radii
have to be increased.
Results > Result variables ... > Contact distance above > Dismiss
User interface
User interface
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Display of the result value Contact distance above with min value 0
and max value 1
You can see that the part is not formed out completely in the area of
the dome, in particular at the radii in this region.
Simulation predicts cracks in the area of the dome when using the
load control method specified here. In Lesson 2, it will be attempted
to prevent splitting by trying to push material into the forming
zone.
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Read in a simulation
For this example, an existing simulation is used and modified as
required. For this a prepared *.sim file is available, which is based
on Lesson 1.
File > Open
User interface
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Add tool ... > Add tool > Axial start > Use default setting > Add
tool
A new tool was defined of the type Axial start. Now, the name must
be modified:
tool3 > Tool name > Name: axial_start > Enter
Further specification are not required here.
Note:
Note The working direction is set to standard by default. This working direction is then the direction (curved) of the tubing axle. In
addition, it is possible to define for the working direction a vector
(dx
dx dy dz
dz).
The second axial tool is similarly created:
Tools
Add tool ... > Add tool > Axial end > Use default setting > Add tool
> tool4 > Tool name > Name: axial_end > Enter
Thus, the axial tools are defined. Further specification must be only
given now on the Process page.
Input generator: Process
On the Process page, only the process step hydroforming has to be
redefined and must be selected.
The redefined axial tools are set by default to Non active and must
be all inserted with Show.
First, the tool control for axial_start is defined:
Process
hydrofoming > Tool control > axial_start > Control mode: Displcmnt
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Process
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User interface
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Formability
First the simulation is examined with the Formability criterion. The
post variable is activated by clicking the Formability button on the
icons menu located on the right side of the main window (moving
the mouse over each icon shows the label).
It is clearly seen that the critical areas of the dome are now no
longer at risk of splitting (Fig. 2.6).
Fig. 2.6
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Results > Result variables ... > Contact distance above > Dismiss
Results > Ranges ... > Manual > Min.: 0 > Max.: 1 > Return > Dismiss
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Fig. 2.9
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User interface
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Part geometry
Creating a new project
File > New ... > New file > File name: hy_lesson_03 > OK
Meshing and import of CAD geometry
The CAD tool data for this example is provided in IGES format.
Geometry generator > File > Import ... > Import geometry > Format:
IGES > OK > Select a file > Files: hy_lesson_03_tools.igs > OK
This opens the meshing dialog:
Program: afmesh_3.1 > OK
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Title
Tools
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Add tool
Add tool > Axial start > Use default setting > Add tool
tool2 > Tool name > Name: axial_start > Enter
Please use the default settings for tool working direction.
The last remaining tool is axial_end. For this definition, follow the
procedure described for tool axial_start accordingly.
Tools
Add tool
Add tool > Axial end > Use default setting > Add tool
tool3 > Tool name > Name: axial_end > Enter
Please use the default settings for tool working direction. This completes the entries on Tools page for Lesson 3.
Input generator: Tube
Enter the data for the semi finished tube: Tube centerline, outer tube
diameter, material data, etc.
The tube centerline for this lesson is provided in IGESformat
which can be imported as follows:
Tube
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Center axis
This example features a circular cross section. Therefore, definition
can be achieved using the tube outer diameter.
Tube
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Process
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Prebending > Process Step > Type: Prebending > End locked
Annealing
After prebending, define the process step annealing. This stress
relieving procedure may be added after each forming process.
Annealing provides better material forming capabilities for the
main forming process. For calculation purposes, this is achieved by
resetting stresses and strains in the part, yet saving the tube thickness values. You may also change the material properties during
annealing.
Fig. 3.6
Definition of annealing
Initial material: Base material (before annealing)
New material: New material data (after annealing)
Upon working with defaultvalues, AutoFormHydro will calculate with the rvalues data. Optionally you can choose a material
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Process
Please use default values for annealing (Initial material, New material).
Tube Hydroforming
The main, final process step is hydroforming.
hydroforming > Process step > Type: Hydroforming > Pressure
Tool control > Show all > die > Control mode: Stationary
Process
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Fig. 3.8
Dialog: Pressure
Please use the following values as input:
Time: 0 > Pressure: 0
Time: 10 > Pressure: 10 > Add
Time: 40 > Pressure: 40 > Add
Time: 100 > Pressure: 100 > From start > Set
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Fig. 3.9
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Control
Fig. 3.10
ControlMain page
Start of Simulation
File > Save
Input generator
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Part geometry
Preparation of simulation
Open a new simulation file:
File > New ... > New file > File name: hy_lesson_04 > OK
Geometry generator opens.
Importing and Meshing the CAD geometry
The CAD tool data for this example is provided in IGES format.
Geometry generator
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Title
Tools
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Add tool
Add tool > Type of tool: Lateral > Default tool settings: Use settings of tool: die > Add tool
For this tool name, the geometry working direction must be
defined.
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Fig. 4.4
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Curve manager
Import lines menu opens.
Import line(s) > Format: IGES > OK > Select a file > Files:
hy_lesson_04_axis.igs > OK > Program: afmesh_3.1 > OK
Imported lines are displayed in main display and in Curve manager
as Curve 1 and Curve 2. These two lines are the center line of the
tube and working direction of the counter tool respectively.
Close Curve manager.
Curve manager > File > Dismiss
Use Copy from on Tools page of Input generator to define working
direction.
countertool > Working direction: Copy f. ...
Select curve menu opens.
Select green line with right mouse button. In Curve manager it can
be seen that green line is Curve 2.
Select curve > OK
AutoForm - Question menu for determination of orientation opens.
AutoForm - Question > Keep
Option 2: Use Import option on Tube page.
Tube
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Tools
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Add tool
Add tool > Type of tool: Axial end > Use default setting > Add tool
tool4 > Tool name > Name: axial_end > Enter
axial_end > Working direction: Automatic
Inputs for tools are completed.
Input generator: Tube
Tube center line must be specified.
Curves are already imported. Tube center line can be defined using
Copy from option.
Tube
Tube
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User interface
Fig. 4.8
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Curve editor
Hydroforming
Now Hydroforming must be defined (Fig. 4.10). Select subpage
hydroforming on the Process page.
Process
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Input generator
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