Particularly high quality demands are associated with outer panels. One has to do meet these requirements during the development of the tool geometry and the layout of the forming process, This lesson describes the basic procedures for the simulation of outer panels in detail. A complete discussion of all the important aspects of quality regarding outer panels cannot be covered, however, in the contexf of this workshops.
Main Focus
Symmetry, half input
Generating wiper tool and wiper direction
Drawing stage with inner binder
Outer binder with butterfly
Determining initial blank outline using AutoForm-Blank generator
Determining drawbead force using Drawbead generator
Checking binder closing and first punch contact
Evaluation of the surface quality
Used Software
AutoForm-DieDesigner
AutoForm-Blank generator
AutoForm-Incremental
Setting up a New Simulation and Importing the Part
For this lesson, the part geometry (left-hand half of a symmetrical single action part) is available in af format. The right-hand part is designed automatically in AutoForm as a reversed image to the left-hand half.
few ... > New file > File name: pp_lesson_J)5 > Import File > File format: a f > Directories: Select the folder containing the file > Files: pp_Iesson_05.af > OK
Part Geometry Stage Defining the Symmetry Plane
Determine the symmetry plane on which the left-hand half of the part is mirrored. The two parts are tipped into the drawing position (Tip page) a little later.
Pre > Symmetry / double attached > Symmetry, half input
For symmetrical single-action parts select type of geometry Symmetry, half input. Normally, the xz plane with y = 0 is the symmetry plane in the vehicle coordinate system.
Symmetry plane: Automatic
The part geometry is now completely available and does not need to be modified either. For this reason the individual geometry stages are now being set up.
The part is produced in three operations. The drawing stage OP20 is followed by the cutting operation OP30 and then the hemming flange is restruck in OP40,
Add Wio?r Staoe 40
Insert a new geometry stage for the wiper operation as geometry stage 40.
Add ... > Add stage > Tag: 40 >Type: Form > OK
Geometry Stage 40: Wiper Tools Go to the Wiper page.
Form 40 Wiper > Add wiper
The definition of the wiper requires the specification of at least the geometry which is transformed in operation 40. This is the flange itself, as well as the radius between the flange and the part.
Enter the necessary surface into the appropriate register:
Form 40 Wiper > Select the flange surface > Wiper region: Wall
In order to facilitate die selection of the radius faces, click on Display wall.
Put the necessary radius faces in the appropriate register:
Form 40 Wiper > Select the radius faces with the right-hand mouse button
> Wiper region: Radius
Thus the geometry definition is complete and the specifications for the wiper geometry can be defined.
The flange being measured is one of 7 mm. For this reason a height of 25 mm is sufficient for the wiper geometry.
Wiper geometry > Height: 25.00
Use the button
Form 40 Wiper > Apply
to generate the wiper geometry and the wiper directions.
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