This workshop shows you how to work with AutoForm-Sigma on the basis of a simple example. The mode of operation of AutoForm-Sigma is presented considering an automotive reinforcement as example.
The main fields of application of AutoForm-Sigma are:
? Process improvement - Performance analysis —for the
design of robust products and processes that guarantee quality requirements in manufacturing
? Process improvement - Optimization —for the optimization of products and processes by finding the best parameters for them
? Robustness—for the improvement of the manufacturing process through the reduction of noise influences on the quality of the product in the manufacturing
Each of these areas of application will receive its due in a separate lesson. The layout of the lessons is oriented towards the recommended course of the project. Each of the lessons begins with a basic simulation and continues to discuss the various applications. Each lesson can also be handled independently of the other ones.
Lesson 1: Process Improvement—Performance Analysis
This lesson presents the application of AutoForm-Sigma in the field of Process improvement—Performance analysis: Sensitivity and influence of several design parameters.
Main Focus
? Performance analyses
? Defining design variables
? Evaluation of the sensitivity analysis
Used Software
? AutoForm-DieDesigner
? AutoForm-Incremental
? AutoForm-Sigma
Open the simulation file rb_lesson_01.sim.
Main Window File > Open > Select a file > Directories: Select the folder
containing the file > File: rb_lesson_01.sim > OK
Open the Process generator and insert the Sigma page in the Process generator. Use the command:
The Analysis Type Options
Select the type of analysis.
? RE: Design improvement/ optimization: Optimization is carried out to obtain the best parameter set to achieve a predefined quality target.
? RM: Performance Analysis NOISE: Parameter study used for robustness, quality and process capability analyses; variables obtain a normal distribution within the parameter range.
" RE: Performance Analysis DESIGN: Parameter study used for sensitivity and influence analyses; variable obtains a uniform distribution within the parameter range.
? RE: REGULAR GRID scan (1-2 DVs): Parameter study; variables are distributed according to a regular grid within the parameter range.
In the case at hand, the process type RE: Performance Analysis DESIGN is selected.
Sigma Setup > Analysis type > Analysis type: RE: Performance Analysis
DESIGN
Defining Design Variables
The next step is the definition of the design parameters for the sensitivity analysis. The design parameters are those parameters which exert a significant influence on the forming process and which can be defined by the process engineer. In the case at hand, the restraining force of the drawbeads and the geometry of the addendum are varied.
Drawbeads
Go to the Drwbds page in the Process generator. The variation of the three drawbeads ranges from "no drawbead" (Forcefactor = 0.0) to the Strong option (Forcefactor = 0.9).
Parameters that can be used as design variables can be recognized by the yellow framed input field. Right-click in the field Restraining/Force factor [-] in the Strength area. The dialog Add/ edit design variable appears:
Options for the Definition of Design Variables
? Name: Name of design variable
? Dependent: Name of a defined design variable. The current design variable depends on a selected, already defined design variable.
? Independent: Definition of an independent design variable
? Min: Smallest possible value of the design variable
? Max: Largest possible value of the design variable
Complete the entries on the force factor of the first drawbead in the Design variable definition area of the Add/ edit design variable.
DrwbdS beadl > Name: dbl > Dependent: independent > Min: 0 >Max: 0.9
>OK
Now the background color of the field changes (yellow). This helps you see that this parameter was defined as a design variable. The Drwbds page is highlighted yellow.
Accordingly, define the design variables for drawbeads bead2 ad bead3:
bead2 > Name: db2> Dependent: Independent > Min: 0 >Max: 0.9 >OK
bead3 > Name: db3 > Dependent: Independent > Min: 0 > Max: 0.9 >OK
Addendum
The other parameters, which vary for the sensitivity analysis, concern the tool geometry. Open the Geometry generator
http://www.cadfamily.com/html/Article/AutoForm-Robustness_605_1.htm
http://www.cadfamily.com/html/Article/AutoForm-Robustness_605_2.htm
http://www.cadfamily.com/html/Article/AutoForm-Robustness_605_3.htm
http://www.cadfamily.com/html/Article/AutoForm-Robustness_605_4.htm
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