eta/DYNAFORM Version 5.5 software is an LS-DYNA-based sheet metal forming simulation solution package developed by Engineering Technology Associates, Inc. The specialty CAE software combines the analysis power of LS-DYNA Versions 960 and 970 with the streamlined pre- and post-processor functions. These analysis codes and interactive functions are uniquely integrated to service the sheet metal forming industry in tooling design and development. The program also maximizes traditional CAE techniques to reduce prototyping costs and lead 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 capabilities for solving fluid and solid structural problems. The 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 associated cost for producing high quality 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 tearing, 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 and NT operating systems of 1998 and above. For LINUX, the Red Hat version 7.2 and above is supported.
Special features of eta/DYNAFORM Version 5.5 include:
Add new Setup module- AUTOSETUP
This is a brand new module in the eta/DYNAFORM 5.5. This module is process oriented and enables user to easily setup the simulation parameters. Currently, both Sheet Metal Forming and Tubular Hydroforming interfaces are implemented in the Auto-Setup. In the Sheet Metal Forming interface, the local system coordinate can be defined so that the local Z axis can be set as the stamping direction. Moreover, the tailor welded and the laminated blanks are supported.
Update Drawbead function
The Drawbead function is updated based on the practical need. Compared with the drawbead function in former version, the latest drawbead function is improved in all kind of aspects. In previous version, it is very inconvenient for user to define and edit the drawbead. In eta/DYNAFORM 5.5, the GUI of drawbead and operation style is overhauled to facilitate easy drawbead definition and modification. All the operation in drawbead, including property definition, create, edit and restrain force definition, can be easily done without advanced training.
Improved Multiple Parts Nesting
In eta/DYNAFORM5.5, the arithmetic of Multiple Parts Nesting function is improved and optimized. The result of auto nesting for multiple parts is more practical than former version. At the same time the material utilization is also enhanced.
More functional DFE module
Based on the eta/DYNAFORM5.2, some functions of the DFE module in eta/DYNAFORM 5.5 are improved and added to satisfy the need of the friendly and functional operation. The major improvement includes:
Ø Added the TRIM LINE function. This function enables user to unfold the flange to the addendum created in eta/DYNAFORM and provide the accurate trim line for the subsequent trim operation.
Ø Added the Re-ENGINEERING module. This function enables user to convert the addendum which was designed by CAD software to the addendum in eta/DYNAFORM¡¯s DFE module. User can modify the addendum with tools provided in eta/DYNAFORM¡¯s DFE environment. Another key function of the Re-Engineering is the migration of addendum design from a part to another part which has minor shape change. Such capability reduces time in draw die design.
Ø The INNER FILL function in DFE module is drastically improved. User can fill both inner and boundary hole through defining some auxiliary lines. This function is very useful for user to fill the large hole, such as the window area of doors, lift gates, etc.
Ø In TIPPING and OUTER SMOOTH functions, user can select different part to perform Tipping and Smooth function.
Enhanced Pre-processor functions
Ø Added the Delete function in the Part menu to allow removal of more than one part each time the function is activated.
Ø Improved Combine Line function.
Ø The Line Offset function is improved. A closed line will be created after offsetting a selected closed line.
Ø Improved line Re-space function.
Ø Improved the Element Split function. The *Constraint Adaptive keyword will be generated after divided the elements of stamped part.
Ø Added the Filter option in the Select Element. The user can select one type of element by filtering element type.
Ø The Mid-Surface function is improved. The user can easily generate the mid-surface of a 3D solid part.
Ø The content of index file is updated to satisfy the need of user. Some basic information defined in preprocessor can be transferred to the eta/POST.
Ø The Model Check and Model Repair function is combined into one dialog box.
Ø The Guide/Pin function is added in the Tool menu. This function is developed to create the column or diamond-like Guide/Pin.
Ø Added the D3plot Curve function in the Utilities/Load Curve menu. This function enables user to set the time or displacement to output the d3plot file during the simulation.
Ø Added the POP Line function. User can define the POP Line in preprocessor, and then the POP line information will be transferred to the eta/POST through index file.
Updated DYNA input file to support LS-DYNA 970 (6367 version)
The LS-DYNA input file created by eta/DYNAFORM 5.5 supports LS-DYNA 970 (6367 version).
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. 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. NUMISHEET¡¯2002 Fender Draw Simulation
Case 2. Double Action of Hemisphere Draw Simulation
Case 3. T-Shape Tubular Hydroforming Simulation
Case 4. NUMISHEET¡¯2002 Fender Gravity Simulation
Case 5. Tailor welded blank and Multi-Stages Simulation
Case 6. U-Channel Springback Simulation
Case 7. Cup Sheet 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 springback simulation.
The eta/DYNAFORM User¡¯s Manual contains function descriptions specifically to the eta/DYNAFORM interface.
For further details on LS-DYNA, please refer to the manuals of the codes published by the LSTC.