AutoForm Trim

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ALGHAFORM PAYLASIMIDIR iletisim: omarer25@hotmail.com www.forum.alghaform.com
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5 AutoFormTrim
AutoFormTrim is a module to determine either a blank outline or a cut contour outline in connection with the AutoFormIncremental solver so that the part reaches the defined target boundary at the end of the forming process. Use AutoFormTrim for the following typical cases: Calculation of the customized blank sheet for crash forming parts Calculation of the customized blank sheet for a predefined target boundary of a drawing part Calculation of the final cut contour in areas in which additional forming steps follow (e.g. second forming, bending operation, flanging operation) Precondition for the calculation of the blank outline and the cut contour is a simulation with AutoFormIncremental containing all necessary forming and cutting operations. Basing on this simulation you define parameters for the calculation of the blank outline and the cut contour. The parameters for the calculation of a blank outline are the target boundary of the part and the forming process after which the target boundary has to be reached. Subsequently the outline of the initial blank is modified iteratively by the simulation of all necessary forming operations until the part has reached the target boundary at the end of the forming process. For the calculation of a cut contour with AutoFormTrim you need the 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 iteratively by the simulation of all necessary forming operations until the part has reached the target boundary at the end of the forming process.
With the current version 3.1 you can only calculate outer cut contours, no hole contours or inner cut contours. The accuracy of the calculation of the blank outline and the cut contour depends on the chordal deviation of the FEA model for the tools and the part.
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Contents of the Workshop AutoFormTrim

Lesson1 Blank outline optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lesson 2
Optimization of a trimming cut outline . . . . . . . . . . . . . . . . . . 11
Lesson 1: Blank outline optimization
5. 1 Lesson 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 blank outline to optimize tr_lesson_01_target.igs: The final outline
The simulation
Open the sim file tr_lesson_01_basis.sim File > Open ... > Select a file > Files: tr_lesson_01_basis.sim > OK Fig. 1.1
The initial geometry
Trim calculation
Open the Input generator and create Trim: Input generator > Create > Trim

Fig. 1.2
Create Trim Then youve got a new page in the Input generator called Trim. Fig. 1.3
The Trim page in the Input generator On the Trim page, select the option Optimize blank outline: Trim Optimization type > Optimize blank outline Target process step: Process step where you want to get the final part with the correct outline. Target process step: drawing which corresponds to the process step 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 target process step.

Target 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 select curve 2 while pressing the Ctrl key) Max # of iterations: 5 We have to define the maximum number of iterations (maximum number of simulations) Max deviation: 1.2 We have to define the maximum deviation (mm) of the cutting contour from the target boundary. Fig. 1.4 Trim
Selection of the target outline

Fig. 1.5
The Trim 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. 1.6
Start trim In this example, youve got the correct result in just 2 iterations.
Trim results management

AutoForm saves in the trim file (tr_lesson_01_basis.trm) the informations concerning the different iterations it has made, and it creates 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: File > Open trim ... > Select a file > Files: tr_lesson_01.trm User interface Fig. 1.7
The Trim manager manager; open simulation 2 You get access to the following functions: Convergence allows you to check the convergence for each 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 (generally the last one) and then export the optimized cut contour. In order to do so, open the curve manager, select the contour you want to export and export it. Model > Curve manager >Blank outline > File > Export... User interface

Fig. 1.8
Export with the curve manager Fig. 1.9
Blank outline, target boundary and part at the beginning of the calculation of the blank outline with AutoFormTrim

Fig. 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 outline
5. 2 Lesson 2: Optimization of a trimming cut outline

The following example shows how to use AutoFormTrim in order to optimize a trimming cut contour. The following files are needed to run the example: tr_lesson_02_basis.sim: The simulation with the cut outline to optimize tr_lesson_02_target.af: The final outline
The Simulation
Open the sim file tr_lesson_02_basis.sim: File > Open ... > Select a file > Files: tr_lesson_02_basis.sim Fig. 2.1
The initial geometry
11
Trim calculation
Once the simulation is over, open the Input generator and create Trim: Input generator > Create > Trim Fig. 2.2
Create Trim Then youve got a new page in the Input generator called Trim. Fig. 2.3
The Trim page in the Input generator On the Trim page, select the option Optimize cut contour: Optimization type > Optimize cut contour Cut process step: to define the cutting process step where you want to optimize the cut contour. Trim
12

Cut process step > 2_cutting1 which corresponds to the trimming cut operation Target process step: Process step where you want to get the final part with the correct outline. Target process step > 4_abkanten which corresponds to the process step 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 target process step. Trim Target 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 (maximum number of simulations). Max deviation: 1.2 We have to define the maximum deviation (mm) of the cutting contour from the target boundary. Fig. 2.4
Selection of the target outline
13

Fig. 2.5
The Trim 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. 2.6
Start trim In this example, youve got the correct result in just 2 iterations
14
Trim results management

AutoForm saves in the first sim file (tr_lesson_02_basis.sim) the informations concerning the different iterations it has made, and it creates 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 interface Fig. 2.7 File > Open trim ... > Select a file > Files: tr_lesson_02.trm
The Trim manager manager; open simulation 2 You get access to the following functions: Convergence allows you to check the convergence for each 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 (generally the last one) and then export the optimized cut contour. In order to do so, open the curve manager, select the contour you want to export and export it. User interface Model > Curve manager > Cut contour 1 > File > Export...
15

Fig. 2.8
Export with the Curve manager
Miscellaneous informations concerning the correct use of the Trim modulus.

Always remember to select the Write Restart option in the Control page of the Input generator for the basis simulation. The Trim modulus uses this restart file and you wont be able to create a trim without it. Fig. 2.9
Blank outline, target boundary and part at the beginning of the calculation of the cut contour with AutoFormTrim
16

Fig. 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 or blank outline. Try to make two calculations with two different initial cut contours and then compare the results you get with the two computations. If you get the same results, then youve got the correct result. Generally, AutoFormTrim gives the right result in less than 5 iterations.
17
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AutoForm Trim

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iletisim: omarer25@hotmail.

ALGHAFORM PAYLASIMIDIR iletisim: omarer25@hotmail.com www.forum.alghaform.com

Contents of the Workshop AutoFormTrim

Optimization of a trimming cut outline . . . . . . . . . . . . . . . . . . 11

Lesson 1: Blank outline optimization

5. 1 Lesson 1: Blank outline optimization

The initial geometry

Lesson 1: Blank outline optimization

Lesson 1: Blank outline optimization

Selection of the target outline

Lesson 1: Blank outline optimization

Lesson 1: Blank outline optimization

Trim results management

Lesson 1: Blank outline optimization

Export with the curve manager Fig. 1.9

Lesson 1: Blank outline optimization

Lesson 2: Optimization of a trimming cut outline

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

The initial geometry

Lesson 2: Optimization of a trimming cut outline

Lesson 2: Optimization of a trimming cut outline

Selection of the target outline

Lesson 2: Optimization of a trimming cut outline

Lesson 2: Optimization of a trimming cut outline

Trim results management

Lesson 2: Optimization of a trimming cut outline

Export with the Curve manager

Miscellaneous informations concerning the correct use of the Trim modulus.

Lesson 2: Optimization of a trimming cut outline

Lesson 2: Optimization of a trimming cut outline

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