INTRODUCTION
eta/DYNAFORM Version 5.2 software is an LS-DYNA-based sheet metal forming simulation solution package developed by Engineering Technology Associates, Inc. This specialty CAE software combines the analysis power of LS-DYNA Versions 960 and 970 with the streamlined pre- and post-processor functions of eta/DYNAFORM. These analysis codes and interactive functions are uniquely integrated to service the sheet metal forming industry in tooling design and development. This program also maximizes traditional CAE techniques to reduce prototyping costs and cycle time for product development.
eta/DYNAFORM's analysis engine is LS-DYNA, which is developed and currently supported by the Livermore Software Technology Corporation (LSTC) of Livermore, California. It is a general purpose, non-linear, dynamic, finite element analysis code utilizing explicit and implicit solver approaches for fluid and solid structural problems. This code has been developed for applications such as automobile crashworthiness, occupant safety, underwater explosion, and sheet metal forming.
The bottleneck of the metal forming development cycle is the hard tooling design lead-time. The eta/DYNAFORM CAE approach simulates this tooling process and thereby reduces the tooling tryout time and the cost of producing high quality panels and stamped parts. eta/DYNAFORM effectively simulates the four major design concerns in the tooling process: Binder Wrap, Draw Die, Spring Back, and Multiple Stage Tooling. These simulations enable engineers to conduct feasibility studies of a product design early in the design cycle.
eta/DYNAFORM features well-defined tooling surface data to predict the performance of a stamping for areas such as cracking, wrinkling, and thinning, in addition to predicting skid mark and spring back effects.
Availability:
eta/DYNAFORM is available for all UNIX workstation platforms including DEC(Alpha), HP, IBM, SUN, and SGI. It is available on PC for Windows NT operating systems of 1998 and above. For LINUX, the RedHat version 7.2 and above is supported.
Special features of eta/DYNAFORM Version 5.2 include:
Die Face Engineering - Significantly enhanced features and functions to support die face geometry:
Ø Inner Binder function enables the user to create multiple binders.
Ø Enhanced edit function of the binder and the binder trim function. In symmetrical models, the binder surface at the symmetry edge is smoother.
Ø A grid function has been added to provide points for defining section lines in the Free Form Binder function.
Ø Enhanced addendum functions have been provided such as COPY, MOVE and PROFILE SYMMETRY, SPLIT and SHOW ADDENDUM, ELONGATION of profile, CREATE PROFILE LINE and CREATE ADDENDUM SURFACE.
Added MSTEP function
MSTEP - An iterative one-step code to support blank size estimation applications and quick formability assessment has been added. It provides the user an early forming result and blank outline in minutes. The EVALUATION REPORT function creates a detailed blank size estimation result report for the user.
Added Nesting function
A blank nesting function accounting for the carrier and supporting progressive tooling applications is now included. One-up nesting, two-pair nesting, two-up nesting, and multiple blank nesting methods are provided according to production requirements. The utilization of the blank and other nesting information can be printed in a nesting report.
Added Surface Mapping function
The SURFACE MAPPING function enables the user to map the original CAD surface data to the deformed blank mesh for CNC processing.
Default Parameters and Configuration Control
eta/DYNAFORM provides a two-level authorization system to enable the supervisor or super-user to implement default values and parameters in addition to customizing processes and applications.
The DYNAFORM DEFAULT file, located in both the program installation directory and the user's home directory, allows a user to modify default parameters including file extensions, contact parameters, adaptive mesh parameters, output control parameters, etc.
A detailed explanation regarding the default parameters is provided at the beginning of the DYNAFORM DEFAULT file.
Enhanced Pre-processor functions
Updated DYNA input file to support LS-DYNA 970
The DYNA file created by eta/DYNAFORM 5.2 supports LS-DYNA 970.
Documentation
A Training Manual is available to assist first time users with the general operating procedures of the program. The manual includes a relatively simple demonstration of a draw die simulation of an S-channel using LS-DYNA describing the process of setting up and running a stamping simulation. The step-by-step procedure guides users through the complete process and flow of tasks. A new user can usually complete the training program and be ready to begin a production project in less than two hours.
The eta/DYNAFORM Applications Manual discusses the basics of the sheet metal forming process and transmits some fundamental knowledge of tooling design and related topics to the user. The following are typical examples of simulations that are included to demonstrate eta/DYNAFORM's capabilities, features, and functions:
Case 1. Binder Wrap Simulation
Case 2. NUMISHEET'93 Fender Simulation
Case 3. Cup Draw Simulation with Adaptive Mesh
Case 4. S-Rail NUMISHEET'96 Simulation with Spring Back
Case 5. Hydroforming Simulation
These workshop examples enable users to fully understand general pre- and post-processing operations in addition to the applications of binder wrap simulation, draw bead force calculation, draw die simulation, Forming Limit Diagram (FLD), thickness, thinning, wrinkling, and spring back simulation.
The User's Manual contains function descriptions specific to the DYNAFORM interface.
For further details on LS-DYNA, refer to the manuals for these codes published by the Livermore Software Technology Corporation.