DYNAFORM 5.8.1 New Features DYNAFORM Team 10/2011

1. DYNAFORM 5.8.1 New Features DYNAFORM Team 10/2011

2. DYNAFORM - LS-DYNA Based Die System Simulation Package BSE (Blank Size Engineering with MSTEP One-Step Solution) Blanking, Nesting, Material Cost Estimation One-Step Formability Simulations DFE (Die Face Engineering) Binder and Addendum Generation, Drawbead Layout NURBS CAD Surface Based Technology Associability – Binder / Addendum Profile / PO Line Re-use existing die face design for new product Incremental solver – INC Solver for design iterative studies Formability (LS-DYNA based Forming Simulation Solution) Accurate Solution for Formability in Springback and Springback Compensation Massive Parallel Processing (CPUs) for analysis lead-time reduction DSA (LS-DYNA based Die System Analysis) Die Structure Integrity (DSI) Sheet Metal Transferring & Handling (SMTH) Scrap Shedding/Removal (SSR)

3. New & Enhanced Features/Functions in DF5.8.1 • Many significant enhancements in all modules • BSE, DFE, INC Solver, Blank Generator, AutoSetup, Job Submitter • Improved GUI which will provide the flow of the process for setting up analyses. • There is no license key change, existing DF5.8 license key is good for DF 5.8.1 • Down load from www.dynaform.com web site and move the license key from DF 5.8 folder to the DF 5.8.1 folder

4. New features of Dynaform New Binder Functions in Dynaform 5.8.1

5. New & Enhanced Features/Functions in BSE Module • Processing Procedure Re-arranged • Enhancement in Nesting Processing • Nesting Calculation to improve the calculation of material utilization rate

6. Outline • Finished items: • Create Binder surface together with mesh • Depth Check in Binder • Auto Move Binder in Part on Binder • Simultaneously Select Symmetrical Elements in Part on Binder

7. 1. Create Binder surface together with mesh • In DF5.8.1, the program will auto mesh Binder with below binder operation: • Create Binder; • Modify Binder ; • Part on Binder; • Butterfly. DF5.8 DF5.8.1

8. 2. Depth Check in Binder Add a check box “Depth” in Binder to check the Draw Deph

9. 3. Auto Move Binder in Part on Binder If there is a larger gap between Binder and Product, then do Part on Binder operation, it often cannot get good result. In DF5.8.1, after click Apply to do Part on Binder, the program will auto to move binder to the closest position of Product, then do the Part on Binder operation.

10. 3. Auto Move Binder in Part on Binder The below are the Part on Binder result of DF5.8 and DF5.8.1. The white region will be on binder, and the gap between binder and product is 80mm. DF5.8.1 Result DF5.8 Result

11. 4. Simultaneously Select Symmetrical Elements in Part on Binder If symmetry plane has been defined for symmetric part and Double-Attached Half/Full, it will support to simultaneously select elements on both sides in Part on Binder.

12. New features of Dynaform New DFE Functions in Dynaform 5.8.1 Date: 08/31/2011

13. Outline • New functions as below • Load and mesh automatically; • Only add Middle surfaces part in Current Tool; • Only add Top or Bottom surfaces part in Current Tool; • Define Tipping before Symmetry; • Auto check symmetry plane for full input symmetrical part; • New Auto Tipping Method ‘Element Normal’; • Parameterization Inner Fill, support to simultaneously create and edit symmetrical holes; • Parameterization Boundary Smooth, support to simultaneously create and edit smooth features; • Simultaneously create and edit symmetrical control points on double fill control line; • Simultaneously create and edit symmetrical Side Step features; • Product Replace; • Update Boundary Fill features

14. 1. Load and mesh automatically • Outlines of Import Options: • Provide option: Import Line, Import Surface and Auto Mesh in Import GUI. • The options are included in Tool preparation of BSE,DFE and Auto Setup modules. • Description: • The options under file menu of Tool preparation. • User can select line or surface option to import models. • When selected import surface, the mesh option will be active, and user can set the mesh parameters.

15. 2. Only add Middle surfaces part in Current Tool; In Preparation, the program will automatically add the middle surface layer to the current tool and remove other layers in the current tool after the Generate Middle Surface is generated. Current Tool List After generate middle surface Current Tool List Before generate middle surface

16. 3. Only add Top or Bottom surfaces part in Current Tool; In Preparation, after separate surfaces, the dialog box Add to current tool pop up. Allow user to add the top or bottom surface layers of the part to the current tool, and remove other layers in the current tool. Current Tool List After separate surface Current Tool List Before separate surface

17. 4. Define Tipping before Symmetry Add a option in Edit Default Config to define Tipping before Symmetry

18. 5. Auto check symmetry plane for full input symmetrical part In DF5.8.1, add Apply button to check that the product is symmetrical about defined symmetry plane. If it is symmetrical, the symmetry plane is successfully defined. If not, the user needs to redefine the symmetry plane. DF5.8 DF5.8.1

19. 6.New Auto Tipping Method Element Normal: New auto tipping method, use the average normal of selected elements as Draw Direction. DF5.8 DF5.8.1

20. 7. Parameterization Inner Fill • New changes in Inner Fill as below: • Parameterization Inner Fill • Simultaneously fill selected symmetrical holes • Simultaneously add and edit profile on symmetrical holes. • Simultaneously add and edit profile on hole which cross symmetry plane. DF5.8.1 DF5.8

21. 7. Parameterization Inner Fill • Parameterization Inner Fill: Use new GUI in DF5.8.1, save all fill features, parameters and profile in database, support to re-edit. • Auto: Fill all holes one time • Manual: File one hole one time • List: Record all filled holes • Profile: Add and edit profile on hole region to obtain special fill result

22. 7. Parameterization Inner Fill 2. Simultaneously fill selected symmetrical holes one time. Select one hole, the symmetrical will auto highlight same time. Symmetrical holes Before Fill After Fill

23. 7. Parameterization Inner Fill 3. Simultaneously add and edit profile on symmetrical holes

24. 7. Parameterization Inner Fill 4. Simultaneously add and edit profiles on hole which cross symmetry plane. Note: 1. Add a profile which will crossing symmetry plane, it will auto be vertical to symmetry plane. 2. Support to simultaneously create symmetrical profiles on both sides. 3.Support to simultaneously edit both symmetrical profiles.

25. 8. Parameterization Boundary Smooth New Changes in Boundary Smooth as below: • Change the name from “Outer Smooth” to “Boundary Smooth” • Parameterization Boundary Smooth • Support to create boundary smooth feature on inner boundary • Simultaneously smooth boundary on both side • Simultaneously edit smooth region • Simultaneously add and edit profile • Create smooth features cross symmetry plane DF5.8 Outer Smooth DF5.8.1 Boundary Smooth

26. 8. Parameterization Boundary Smooth Parameterization Smooth: save all fill features, parameters and profile in database, support to re-edit. • Global: Smooth selected one time • Local: Smooth by defined boundary on the selected boundary • List: Record all smooth features • Boundary: Edit position and shape of smoothed boundary. • Profile: Add and edit profile on smooth feature Note: 1. After click Add, user need to select out boundary or an inner boundary to smooth firstly. 2. All smooth features, parameters and profile will be saved in database, support to re-edit them.

27. 8. Parameterization Boundary Smooth 3. Support to Create smooth feature on inner boundary: Select a hole as smooth boundary. After click Add button, then select a hole boundary to smooth. Note: When smooth hole boundary, only Local method can be used.

28. 8. Parameterization Boundary Smooth 4. Simultaneously smooth boundary on both side: Program will create smooth result on symmetrical boundary one time

29. 8. Parameterization Boundary Smooth 5. Simultaneously edit End Points position and edit smooth boundary’s shape

30. 8. Parameterization Boundary Smooth 6. In DF5.8.1, support to Simultaneously add and edit profile, to obtain special smooth result

31. 8. Parameterization Boundary Smooth 7. The Local Smooth supports to cross Symmetry Plane to create Boundary Smooth After defining a symmetry plane and selecting a point on the boundary, the Symmetry Option dialog box will display. Click the Cross Symmetry Plane option, and the program will automatically connect the ends of the two sides of the symmetry plane to generate the smooth outline, The created local smooth outline will pass through the symmetry plane. Toggle on the option

32. 9. Simultaneously edit Double Fill Use new Curve Editor to edit Double Fill control lines, and support below symmetry operation: • Add Point • Remove Point; • Modify value in Curve Editor dialog; • Move point in display region.

33. 10. Simultaneously create and edit Side Step • Support to symmetrically create and edit Side Step • Re-arrange GUI • Support to create Side Step on Inner Boundary • Create on both side for symmetrical die face same time • Support to cross Symmetry Plane to create Side Step

34. 10. Simultaneously create and edit symmetrical Side Step • Re-arrange GUI DF5.8 DF5.8.1

35. 10. Simultaneously create and edit symmetrical Side Step 2. Create Side Step on Inner Boundary. Clicking Add button and selecting four control points on the inner boundary, the Side Step will be created on the inner boundary

36. 10. Simultaneously create and edit symmetrical Side Step • 3. Simultaneously create symmetrical Side • Simultaneously select end point on both side. • Simultaneously edit control line on both side.

37. 10. Simultaneouslycreate and edit symmetrical Side Step 4. Support to cross Symmetry Plane to create Side Step When the Side Step is created on the Symmetry Part, the Symmetry Option dialog box will display. Click the Cross Symmetry Plane option, and the program will automatically connect the control points of the two sides of the symmetry plane to generate the control line of Side Step. The created Side Step will pass through the symmetry plane. Toggle on the option

38. 11. Product Replace 10. Product Replace: Add a new option in Preparation File menu. Allow the user to replace the initial product(Has created die face) with the modified product. Replace the existing product by importing a new product. Note: As the initial product has created the die face, the program will automatically mesh the new product imported and define the die face type to adjust the tipping.

39. 11. Product Replace Product Replace for Double_Attached If the initially defined product type is Double-Attached, click Replace button, there are the Left and Right options, which allows the user to replace the Left and Right simultaneously, or only one of them.

40. 11. Product Replace Auto Mesh: As the initial product has created the die face, the program will automatically mesh the new product imported and define the die face type to adjust the tipping. Mesh Parameters: Allow user to modify the mesh parameters.

41. 12. Update Boundary Fill features 11 Update Boundary Fill features UPDATE When the user replaces the current product, or changes the part shape or part position, or edit created boundary features by other operations, the Update button will turn to red. Click this button and the program will automatically update the created boundary fill features.

42. New features of Dynaform New Addendum Functions in Dynaform 5.8.1 Date: 09/22/2011

43. Outline • Finished items: • Symmetrical Create Addendum: Outer, Inner or Corner. • Symmetrical Edit Addendum Feature Line • Symmetrical Edit and Delete Profile • Symmetrical Orient Profile Direction • Add Trim Binder in Addendum • New Develop Trim Line function: Geometry and MStep • Quick Link to AutoSetup

44. 1. Symmetrical Create Addendum • Symmetrical Create Addendum: Outer

45. 1. Symmetrical Create Addendum • Symmetrical Create Addendum: Inner

46. 1. Symmetrical Create Addendum • Symmetrical Create Addendum: Corner.

47. 2. Symmetrical Edit Addendum Feature Line 2. Symmetrical Edit Addendum Feature Line Note: If symmetry plane has been defined for symmetric part and Double-Attached Half/Full parts, Merge, Split and Combine functions will be de-activated.

48. 3. Symmetrical Edit Profile parameters, Symmetrical Insert and Delete Profile 3. Symmetrical Edit Profile parameters, Symmetrical Insert and Delete Profile

49. 4. Symmetrical Orient Profile Direction 4. Symmetrical Orient Profile Direction

50. 5. Add Trim Binder in Addendum Move Trim Binder from Modification to Addendum DF5.8 DF5.8.1