AutoForm Trim

7/28/2019 AutoForm Trim

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ALGHAFORM PAYLASIMIDIR

www.forum.alghaform.com

iletisim: [email protected]


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5555 AutoFormTrimAutoFormTrimAutoFormTrimAutoFormTrim

AutoFormTrim is a module to determine either a blank outline or acut contour outline in connection with the AutoFormIncrementalsolver so that the part reaches the defined target boundary at theend of the forming process. Use AutoFormTrim for the followingtypical cases:

Calculation of the customized blank sheet for crash form-ing parts

Calculation of the customized blank sheet for a predefinedtarget boundary of a drawing part Calculation of the final cut contour in areas in which addi-

tional forming steps follow (e.g. second forming, bendingoperation, flanging operation)

Precondition for the calculation of the blank outline and the cutcontour is a simulation with AutoFormIncremental containing allnecessary forming and cutting operations. Basing on this simulationyou define parameters for the calculation of the blank outline and

the cut contour.

The parameters for the calculation of a blank outline are the targetboundary of the part and the forming process after which the targetboundary has to be reached. Subsequently the outline of the initialblank is modified iteratively by the simulation of all necessaryforming operations until the part has reached the target boundaryat the end of the forming process.

For the calculation of a cut contour with AutoFormTrim you needthe following input:

Cut contour to be optimized Target boundary for the part Forming process after which the target boundary has been

reached

Subsequently the contour of the defined cut is modified iterativelyby the simulation of all necessary forming operations until the part

has reached the target boundary at the end of the forming process.

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With the current version 3.1 you can only calculate outer cut con-tours, no hole contours or inner cut contours.

The accuracy of the calculation of the blank outline and the cut con-tour depends on the chordal deviation of the FEA model for the

tools and the part.



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Contents of the Workshop AutoFormTrimContents of the Workshop AutoFormTrimContents of the Workshop AutoFormTrimContents of the Workshop AutoFormTrim

Lesson1Lesson1Lesson1Lesson1 Blank outline optimizationBlank outline optimizationBlank outline optimizationBlank outline optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .4444

Lesson 2Lesson 2Lesson 2Lesson 2 Optimization of a trimming cut outlineOptimization of a trimming cut outlineOptimization of a trimming cut outlineOptimization of a trimming cut outline . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 11111111



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Lesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimization

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5. 15. 15. 15. 1 Lesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimizationLesson 1: Blank outline optimization

The following example shows how to use AutoFormTrim in order to optimize a blank

outline.

The following files are needed to run the example:

tr_lesson_01_basis.sim: The simulation with the blankoutline to optimize

tr_lesson_01_target.igs: The final outline

The simulationThe simulationThe simulationThe simulationOpen the sim file tr_lesson_01_basis.sim

File > Open ... > Select a file > Files: tr_lesson_01_basis.sim > OK

Fig. 1.1Fig. 1.1Fig. 1.1Fig. 1.1

The initial geometry

Trim calculationTrim calculationTrim calculationTrim calculationOpen the Input generator and create Trim:

Input generator > Create > Trim



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Fig. 1.2Fig. 1.2Fig. 1.2Fig. 1.2

Create TrimTrimTrimTrim

Then youve got a new page in the Input generator called Trim.

Fig. 1.3Fig. 1.3Fig. 1.3Fig. 1.3

The TrimTrimTrimTrim page in the Input generator

On the Trim page, select the option Optimize blank outline:

TrimTrimTrimTrim Optimization type > Optimize blank outline

Target process step: Process step where you want to get the finalpart with the correct outline.

Target process step: drawing which corresponds to the process stepwhere we want to get the correct outline at the end of the step.

Target Boundary: To give the correct target outline.

We must give the final outline we want to get at the end of the tar-get process step.



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TrimTrimTrimTrimTarget boundary > Import > IGES > tr_lesson_01_target.igs >Curve 1 and Curve 2 > OK

(To select both Curve 1 and 2, first select curve 1 and then selectcurve 2 while pressing the Ctrl key)

Max # of iterations:5

We have to define the maximum number of iterations (maximumnumber of simulations)

Max deviation:1.2

We have to define the maximum deviation (mm) of the cutting con-

tour from the target boundary.

Fig. 1.4Fig. 1.4Fig. 1.4Fig. 1.4

Selection of the target outline



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Fig. 1.5Fig. 1.5Fig. 1.5Fig. 1.5

The TrimTrimTrimTrim page at the end of the input

Now you can launch the Trim calculation:

File > Save as > tr_lesson_01.trm

Job > Start trim > Save > Start

Fig. 1.6Fig. 1.6Fig. 1.6Fig. 1.6

Start trimStart trimStart trimStart trim

In this example, youve got the correct result in just 2 iterations.



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Trim results managementTrim results managementTrim results managementTrim results managementAutoForm saves in the trim file (tr_lesson_01_basis.trm) the infor-mations concerning the different iterations it has made, and it cre-ates files for each iteration of the Trim modulus(tr_lesson_01_basis_trm1.sim, tr_lesson_01_basis_trm2.sim etc.).

Open the file tr_lesson_01_basis.trm to open the Trim manager:

User interfaceUser interfaceUser interfaceUser interfaceFile > Open trim ... > Select a file > Files:tr_lesson_01.trm

Fig. 1.7Fig. 1.7Fig. 1.7Fig. 1.7

The Trim managerTrim managerTrim managerTrim manager; open simulation 2222

You get access to the following functions:

Convergence allows you to check the convergence foreach simulation and then choose the best one. Open allows you to choose which simulation you want to

open, the basis simulation or one of the trim simulation.

Then you can choose the simulation you want to open (generallythe last one) and then export the optimized cut contour.

In order to do so, open the curve manager, select the contour youwant to export and export it.

User interfaceUser interfaceUser interfaceUser interfaceModel > Curve manager >Blank outline > File > Export...



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Fig. 1.8Fig. 1.8Fig. 1.8Fig. 1.8

Export with the curve manager

Fig. 1.9Fig. 1.9Fig. 1.9Fig. 1.9

Blank outline, target boundary and part at the beginning of the cal-

culation of the blank outline with AutoFormTrim



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Fig. 1.10Fig. 1.10Fig. 1.10Fig. 1.10

Blank outline, target boundary and part after the calculation of the

blank outline with AutoFormTrim



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Lesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outline

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5. 25. 25. 25. 2 Lesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outlineLesson 2: Optimization of a trimming cut outline

The following example shows how to use AutoFormTrim in order to optimize a trim-

ming cut contour.

The following files are needed to run the example:

tr_lesson_02_basis.sim: The simulation with the cut out-line to optimize

tr_lesson_02_target.af: The final outline

The SimulationThe SimulationThe SimulationThe SimulationOpen the sim file tr_lesson_02_basis.sim:

File > Open ... > Select a file > Files: tr_lesson_02_basis.sim

Fig. 2.1Fig. 2.1Fig. 2.1Fig. 2.1

The initial geometry



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Trim calculationTrim calculationTrim calculationTrim calculationOnce the simulation is over, open the Input generator and createTrim:

Input generator > Create > Trim

Fig. 2.2Fig. 2.2Fig. 2.2Fig. 2.2

Create TrimTrimTrimTrim

Then youve got a new page in the Input generator called Trim.

Fig. 2.3Fig. 2.3Fig. 2.3Fig. 2.3

The TrimTrimTrimTrim page in the Input generator

On the Trim page, select the option Optimize cut contour:

TrimTrimTrimTrimOptimization type > Optimize cut contour

Cut process step: to define the cutting process step where you want

to optimize the cut contour.



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Cut process step > 2_cutting1 which corresponds to the trimmingcut operation

Target process step: Process step where you want to get the finalpart with the correct outline.

Target process step > 4_abkanten which corresponds to the processstep where we want to get the correct outline at the end of the step.

Target Boundary: To give the correct target outline.

We must give the final outline we want to get at the end of the tar-get process step.

TrimTrimTrimTrimTarget boundary > Import > af > Keep orientation >tr_lesson_02_target.af > Curve 4 > OK

Max # of iterations: 5

We have to define the maximum number of iterations (maximumnumber of simulations).

Max deviation: 1.2

We have to define the maximum deviation (mm) of the cutting con-tour from the target boundary.

Fig. 2.4Fig. 2.4Fig. 2.4Fig. 2.4

Selection of the target outline



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Fig. 2.5Fig. 2.5Fig. 2.5Fig. 2.5

The TrimTrimTrimTrim page at the end of the input

Now you can launch the Trim calculation:

File > Save as > tr_lesson_02.trm

Job > Start trim > Save > Start

Fig. 2.6Fig. 2.6Fig. 2.6Fig. 2.6

Start trimStart trimStart trimStart trim

In this example, youve got the correct result in just 2 iterations



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Trim results managementTrim results managementTrim results managementTrim results managementAutoForm saves in the first sim file (tr_lesson_02_basis.sim) theinformations concerning the different iterations it has made, and itcreates files for each iteration of the Trim modulus(tr_lesson_02_basis_trm1.sim, tr_lesson_02_basis_trm2.sim etc.).

Open the tr_lesson_02_basis.trm file to open the Trim manager:

User interfaceUser interfaceUser interfaceUser interface File > Open trim ... > Select a file > Files: tr_lesson_02.trm

Fig. 2.7Fig. 2.7Fig. 2.7Fig. 2.7

The Trim managerTrim managerTrim managerTrim manager; open simulation 2222

You get access to the following functions:

Convergence allows you to check the convergence foreach simulation and then choose the best one. Open allows you to choose which simulation you want to

open, the basis simulation or one of the trim simulation.

Then you can choose the simulation you want to open (generallythe last one) and then export the optimized cut contour.

In order to do so, open the curve manager, select the contour youwant to export and export it.

User interfaceUser interfaceUser interfaceUser interface Model > Curve manager > Cut contour 1 > File >Export...



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Fig. 2.8Fig. 2.8Fig. 2.8Fig. 2.8

Export with the Curve manager

Miscellaneous informations concerning the correctMiscellaneous informations concerning the correctMiscellaneous informations concerning the correctMiscellaneous informations concerning the correctuse of the Trim modulus.use of the Trim modulus.use of the Trim modulus.use of the Trim modulus.

Always remember to select the Write Restart option in the Controlpage of the Input generator for the basis simulation. The Trim mod-ulus uses this restart file and you wont be able to create a trimwithout it.

Fig. 2.9Fig. 2.9Fig. 2.9Fig. 2.9

Blank outline, target boundary and part at the beginning of the cal-culation of the cut contour with AutoFormTrim



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Fig. 2.10Fig. 2.10Fig. 2.10Fig. 2.10

Blank outline, target boundary and part after of the calculation of

the cut contour with AutoFormTrim

In order to be sure of the Trim computation, follow these advice:

It is better to give a realistic initial trimming cut contour orblank outline.

Try to make two calculations with two different initial cut

contours and then compare the results you get with thetwo computations. If you get the same results, then youvegot the correct result.

Generally, AutoFormTrim gives the right result in lessthan 5 iterations.



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