Manufacturing Solutions 11.0 HyperForm Tutorials

Manufacturing Solutions 11.
0
HyperFormTutorials
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HyperWorks 11.0 Release Notes
Trademark and Registered Trademark Acknowledgments
Listed below are Altair HyperWorks applications. Copyright Altair Engineering Inc., All Rights Reserved for:
HyperMesh 1990-2011; HyperCrash 2001-2011; OptiStruct 1996-2011; RADIOSS 1986-2011; HyperView
1999-2011; HyperView Player 2001-2011; HyperStudy 1999-2011; HyperGraph 1995-2011; MotionView 1993
2011; MotionSolve 2002-2011; HyperForm 1998-2011; HyperXtrude 1999-2011; Process Manager 2003-2011;
Templex 1990-2011; Data Manager 2005-2011; MediaView 1999-2011; BatchMesher 2003-2011;
TextView 1996-2011; HyperMath 2007-2011; ScriptView 2007-2011; Manufacturing Solutions 2005-2011;
HyperWeld 2009-2011; HyperMold 2009-2011; solidThinking 1993-2011; solidThinking Inspired 2009-2011;
Durability Director 2009-2011; Suspension Director 2009-2011; AcuSolve 1997-2011; and AcuConsole
2006-2011.
In addition to HyperWorks trademarks noted above, GridWorks, PBS Gridworks, PBS Professional,
PBS and Portable Batch System are trademarks of ALTAIR ENGINEERING INC., as is patent # 6,859,792. All
are protected under U.S. and international laws and treaties. All other marks are the property of their respective
owners.
Manufacturing Solutions 11.0 Tutorials - HyperForm
HyperForm
........................................................................................................................................... 1
Introduction...................................................................................................................................
to HyperForm
3
Introduction...................................................................................................................................
to HF Macros - HF-0010
5
Introduction
to
HyperBlank
Macros
HF-0010
................................................................................................................................... 11
HF-0100: ...................................................................................................................................
General Introduction
13
Radioss One
Step
...................................................................................................................................
33
HF-0150:
........................................................................................................................................
Quick Setup
35
HF-0200:
........................................................................................................................................
Geometry Cleanup
49
HF-0300:
........................................................................................................................................
Automeshing
65
HF-0400:
........................................................................................................................................
Mesh Quality
81
HF-0500:
........................................................................................................................................
Model Preparation - Undercut Check and Autotipping
89
HF-1000:
........................................................................................................................................
One-Step Stamping Simulation
95
........................................................................................................................................
HF-1010:
Increasing Blankholder Pressures
105
........................................................................................................................................
HF-1020:
Applying Drawbeads and Performing Circle Grid Analysis
109
........................................................................................................................................
HF-1030:
Transferring Forming Results to Crash Analysis
115
........................................................................................................................................
HF-1040:
Laser Weld
123
........................................................................................................................................
HF-1050:
Trim Line Layout
127
Incremental
Analysis
................................................................................................................................... 133
........................................................................................................................................
HF-3000:
Introduction to Incremental_Radioss and Incremental_Dyna
135
........................................................................................................................................
HF-3001:
Auto Process
143
........................................................................................................................................
HF-3002:
User Process
159
........................................................................................................................................
HF-3003:
Setting Up a Multi Stage Simulation from the User Process
175
........................................................................................................................................
HF-3010:
Simple Draw Forming
181
........................................................................................................................................
HF-3020:
Combined Binderwrap and Draw Forming Analysis
191
........................................................................................................................................
HF-3030:
Drawbead
203
........................................................................................................................................
HF-3040:
Springback
213
........................................................................................................................................
HF-3050:
Trimming
219
........................................................................................................................................
HF-3060:
Gravity
225
........................................................................................................................................
HF-3070:
Redraw
227
........................................................................................................................................
HF-3080:
Multi-stage Manager
237
........................................................................................................................................
HF-3090:
Tube Bending
247
........................................................................................................................................
HF-3100:
HydroForming
255
........................................................................................................................................
HF-3110:
Blank Optimizer
265
Die Module
................................................................................................................................... 273
........................................................................................................................................
HF-2005:
Basic Addendum Creation Using Die Process
275
........................................................................................................................................
HF-2010:
Basic Addendum Creation
281
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Proprietary Inform ation of Altair Engineering
........................................................................................................................................
HF-2020:
Designing a Parametric Addendum
287
........................................................................................................................................
HF-2030:
Modifying a Parametric Addendum
307
HF-2040: Parameterization of External Binder and Addendum Section Using Section Editor
........................................................................................................................................
317
Optimization
................................................................................................................................... 327
........................................................................................................................................
HF-4010:
Mesh Morphing
329
........................................................................................................................................
HF-4020:
Optimization 1-Step
337
Result Mapping
................................................................................................................................... 347
........................................................................................................................................
HF-5000:
Using Result Mapper in HyperCrash
349
........................................................................................................................................
HF-5100:
Result Mapping Using Process Manager
357
HF-6000:...................................................................................................................................
Die Structure Optimization
367
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HyperForm
Introduction
HF-0010: Introduction to HF Macros
HF-0100: General Introduction
Radioss One Step Analysis

HF-0150: Quick Setup
HF-0200: Geometry Cleanup
HF-0300: Automeshing
HF-0400: Mesh Quality
HF-0500: Model Preparation - Undercut Check and Autotipping
HF-1000: One Step Stamping Simulation
HF-1010: Increasing Blankholder Pressures
HF-1020: Applying Drawbeads to a Model
HF-1030: Transferring Forming Results to Crash Analysis
HF-1040: Laser Weld
HF-1050: Trim Line Layout
Incremental Analysis
HF-3000: Introduction to Incremental
HF-3001: Auto Process
HF-3002: User Process
HF-3003: Setting Up a Multi Stage Simulation from the User Process
HF-3010: Simple Draw Forming
HF-3020: Combined Binderwrap and Draw Forming Analysis
HF-3030: Drawbead
HF-3040: Springback
HF-3050: Trimming
HF-3060: Gravity
HF-3070: Redraw
HF-3080: Multi-stage Manager
HF-3090: Tube Bending
HF-3100: HydroForming
HF-3110: Blank Optimizer
Die Module
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HF-2005: Basic Addendum Creation Using Die Process

HF-2010: Basic Addendum Creation
HF-2020: Designing a Parametric Addendum
HF-2030: Modifying a Parametric Addendum
Optimization Study
HF-4010: Mesh Morphing
HF-4020: Optimization 1-Step
Result Mapping
HF-5000: Using Result Mapper in HyperCrash
HF-5100: Result Mapping Using Process Manager
HF-6000: Die Structure Optimization

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Introduction to HyperForm
The following introductory tutorials are available:
HF-0010: Introduction to HF Macros

HF-0010: Introduction to HyperBlank Macros

HF-0100: General Introduction to HyperBlank
Radioss One Step Analysis

HF-1000: One-Step Stamping Simulation
HF-1040: Laser Weld
HF-3030: Drawbead
HF-3040: Springback
HF-3050: Trimming
HF-3060: Gravity
HF-3070: Redraw
HF-3080: Multiple Stage Manager
Die Design
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HF-2010: Basic Addendum Creating

HF-2040: Parameterization of External Binder and Addendum Section using Section Editor
Optimization Study
Result Mapping
HF-5000: Result Mapper Using HyperCrash

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Introduction to HF Macros - HF-0010

Radioss One Step process macros
This is the interface for HyperForm with the Radioss One Step macro active. You will see the active browser
for Radioss One Step on the left side of the interface. See the online help for information about the specific
macros that are available.
HyperForm interface w ith One Step tab active
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HyperBlank interface w ith the OneStep tab active
All the Radioss One Step macros are located on the 1Step page of the Utility Menu. These macros allow
you to quickly set up an analysis for one step simulation. The Radioss One Step macros are divided into the
following three sections.
Model
Allows you to import, cleanup, and mesh the model.
Setup
Allows you to setup the model for simulation using Radioss One Step.
Results
Allows you to do post-processing once the analysis is done.

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Radioss One Step Utility menu
Incremental process macros

The following image shows the Utility Menu of the HyperForm interface with Incremental_Radioss user
profile:
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Incremental_Radioss Utility Menu
All of the macros are located in the Radioss page of the macro area. The incremental process macros allow
you to more easily setup different application types. The following application types are available under
Application.

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Form - 1st forming operation setup.

Bend - Tube bending setup.
Hydro - Hydroforming setup.
Blank Opti - Blank Optimizer
TL Opti - Trim Line Optimizer
Die Compensation - Die Compensation macroDepending on the application type chosen, the setup
process contains different macros. The organization of the buttons within the Utility Menu is topdown, guiding you through each step of the specific application type.
Further explanation of each application type is provided in the subsequent tutorials.
Return to HyperForm Tutorials
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Introduction to HyperBlank Macros - HF-0010

HyperBlank process macros
This is the interface for HyperBlank with the OneStep tab active. This is the default setting when HyperBlank
is started. The various macros that are available for HyperBlank are available on the Utility Menu, which is
also on the left side of the interface. See the HyperBlank online help for information about the specific
macros that are available.
HyperBlank interface w ith the OneStep tab active
All the macros are located on the Utility Menu. These macros allow you to quickly set up an analysis for
one step simulation. The macros are divided into the following three sections.
Model
Allows you to import, cleanup, and mesh the model.
Setup
Allows you to setup the model for simulation.
Results
Allows you to do post-processing once the analysis is done.
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HyperBlank Utility Menu
Further explanation of each application type is provided in the subsequent tutorials.
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HyperForm, a subset of Manufacturing Solutions, is a finite element based pre- and post-processor for sheet
metal forming. It combines an extremely fast one-step solver and incremental forming solution using Radioss
as the solver. It also integrates well with the LS-DYNA solver for incremental forming simulation. With the
customized geometry manipulation and mesh generation capabilities, HyperForm enables you to build metal
forming related finite element models, view their results, and perform data analysis.
HyperForm integrates the functionality of HyperMesh and provides engineers at any stage of product design
with quick, valuable, reliable information, reducing the overall product cycle. HyperForm's die module enables
engineers to create and analyze conceptual die designs in order to generate an optimized die. Die concepts
can then be read into any CAD system as a starting block for the actual die build. Integrated with HyperView,
HyperForm can export data in the .h3d format allowing results to be visualized using HyperView Player with
any web browser.
This tutorial introduces HyperForm, as well as many basic concepts and tasks that are needed to get started
with HyperForm, and which serve as pre-requisites for most other HyperForm tutorials. In this tutorial, you
will be introduced to HyperForm from the one-step analysis point of view. The HyperForm interface for
incremental analysis will be described in later tutorials.
This tutorial covers:
Session 1: Fundamental HyperForm user interface
o
User Profiles
Graphics Area
Using the mouse
Tool bar menu
Main menu
Toggles and switches
Utility Menu
The pull-down menus
Session 2: Using the online help

Session 3: File input and output
Session 4: The concept of collector
Session 5: Secondary menus
o
Menu items
Entity selector
Direction selector
Input fields
Pop-up menus
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Function buttons
Session 6: Default HyperForm files
Exercises:
Three exercises are provided in this chapter:
Exercise 1: Opening a database file and using the tool bar
Exercise 2: Understanding Collectors and using online help
Exercise 3: Translating elements
Session 1: Fundamental HyperForm user interface

The HyperForm window consists of these main areas: the graphics area, the User Process tab, the header
bar, the main menu, Utility Menu, and the drop-down menu as shown below. You can access secondary
menus either through their main panel or by using keyboard function keys.
User profiles
The HyperForm user interface includes the following analysis configurations:
Radioss One Step: Setup, run, and review of a one-step analysis
Incremental_Radioss: Setup and run an incremental analysis using RADIOSS Solver
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Die Module: Create and edit binders and addendums

Incremental_LsDyna: Setup and run an incremental analysis using the LS-DYNA solver
After starting HyperForm, the following dialog appears.
In the Applications: field, select Manufacturing Solutions and then select one of the modules - Radioss
One Step, Incremental_Radioss, Incremental_LsDyna, or Die Module - before performing any further
operations.
The selected configuration can include loading a specific template, loading a specific Utility Menu, renaming
panels, removing unused panels or subpanels, and removing, moving, or renaming panel options. The
selected configuration can change the appearance of a panel, but they do not affect the internal behavior of
each function.
Graphics Area
The graphics area displays geometry, models, and XY plots.
Status Bar
The status bar is located at the bottom of the HyperForm window, just below the user profile switches on the
Utility Menu. It displays the name of the current panel and user profile, and model status information.
Messages also appear on the message bar, temporarily overriding the title and status information.
Using the Mouse

The mouse attached to your system is integral to HyperForm and can be used in almost every aspect of user
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input. A two- or three-button mouse can be used with HyperForm.

The mouse buttons have these functions:
Left mouse button
Performs selection operations.
Right mouse button
De-selects entities in the graphics area. Aborts graphics

operations.
Middle mouse button
In the rotate (r) and arc dynamic motion (a) modes,

selects a new center of rotation when you pick a node in
the model.
CTRL + left mouse button
Dynamically rotates the model
CTRL + the middle mouse button
Zooms into an area of the model
CTRL + the right mouse button
Pans the model
Toolbars
Collectors toolbar
Visualization toolbar:
Display toolbar:
The toolbars enable you to manipulate the view of the model, control which collectors are displayed in the
graphics area, set global modeling parameters, and edit solver-specific data.
The functions of some of the toolbar menu icons are described below:
Panel
16
Icon
Description

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Files
Load, save, or import files.
Card edit
Edit solver-specific data in card format
Wireframe
Elements
Draws model geometry as a wire-frame
Shaded
Elements &
Mesh Lines
Draws model geometry in shaded mode
Wireframe
geometry
Draws model geometry as a wire-frame. Click the downward

arrow to choose between excluding and including surface
lines.
Shaded
Geometry &
Surface Edges
Draws model geometry in shaded mode. Click the downward

arrow for options: with edges or without them.
Visualization
Show or hide different types of topology, connector, or

morphing entities. A sub-menu is enabled when this panel is
selected.
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The following viewing icons are available:

Item
Icon
Description
Plot Refresh
Refreshes the graphics area by re-plotting the model
Previous View
Returns to the previous view
Fit View
Resizes the model view to fit the model to the graphics area
Modal Zoom
Circle zoom (left click) / Dynamic zoom (right click).

Left-clicking activates the circle zoom feature. Circle zoom
deactivates after zooming once, or when you click either button
while the pointer is in the graphics area.
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Right-clicking activates the dynamic zoom feature. Once

active, right-click and drag in the graphics area to zoom in/out.
Left-click to deactivate.
Incremental
Zoom
Zoom incrementally; left-click to zoom in, right-click to zoom out
Rotate Mode
Rotate modes: this functions in one of two different ways:

Left-click to activate dynamic rotate mode. Once active, clickand-drag in the graphics area to rotate the model. Right-click to
deactivate.
Right-click to activate dynamic spin mode. Once active, rightclick in the graphics area and hold the mouse button down to
make the model spin. Left-click to deactivate.
Pan modes
Pan modes: this functions in one of two different ways:

Left-click to activate pan mode. Once active, click-anddrag in the graphics area to pan the model view. Right-click
to deactivate
Right-click to activate center mode. Once active, right-click
in the graphics area to change the graphics area center.
Left-click to deactivate.
Rotate (left/
right)
Click the left mouse button to rotate the model leftward, and the
right button to rotate it rightward
Rotate (up/
down)
Click the left mouse button to rotate the model upward, and the
right button to rotate it downward
Spherical
clipping
Use spherical clipping to isolate portions of the model regardless

of component or collector
User View /
True view
Open a pop-up menu used to save and retrieve user-defined or

standard views.
True View
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Exercise 1: Opening a database file and using the toolbar

Step 1: Load the HyperForm Radioss One Step environment file
1.
Start HyperMesh.
2.
On the Preferences menu, click User Profiles.
3.
For Application, select Manufacturing Solutions. Verify that HyperForm and Radioss One Step are
selected.
4.
Click OK.
Step 2: Load the model file

1.
From the File menu, select Open.
2.
In the Open File dialog, change the Files of type: field to All files.
3.
Navigate to the 1Step folder, click on the file Die_Mesh.hm and click Open.
Step 3: Change the visualization of the model

1.
In the Model Browser, expand the Master Model folder, and then Component folder.
2.
Right-click on the Binder component and select Hide. Notice the Binder mesh is no longer displayed in
the graphics area. Right-click on it again and select Show.
3.
From the toolbar, click the Shaded Elements & Mesh Lines icon
shaded mode.
20
to re-draw the model geometry in

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4.
From the toolbar, click the Wireframe Elements icon

mode.
to re-draw the model geometry in wireframe
5.
From the toolbar, click the Element Color Mode icon
and select By Mat from the selection list.
Notice that the Binder and Addendum components become a gray color. This indicates the two
components share the same material.
6.
Repeat step 5 and change the setting back to By Comp.
7.
From the Preferences menu, click Colors.
8.
The graphics area is displayed as a gradient color. You can change both the lighter and darker colors.
Click the color box next to Background 1 and Background 2 and select other color options. This
changes the background color to your selection.
9.
Click Reset to restore the default settings.
10. Click Close to close the dialog.

11. From the toolbar, right-click Pan modes
12. Move the mouse cursor to graphics area, keep on holding the right mouse button and pan the model
graphically.
Move the mouse cursor back to toolbar menu to release the panning action.
Note: Pan action can also be achieved by holding Ctrl keyboard + right mouse button.
13. From the toolbar, left click Rotate Mode icon
to enter dynamic rotate mode.
14. Click and drag in the graphics area to rotate the model.
15. From the toolbar, left click Incremental Zoom icon
16. From the toolbar, click Fit View icon
to zoom in on the model.
to fit the model on the screen.
17. From the toolbar, left click User View / True view icon
to open the user view panel
18. Click the left button to review the model from the XZ plane.
Main Menu
From the main menu you can access to a variety of panels grouped by the selected user profile.
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The main menu w ith the Radioss One Step user profile loaded
Toggles and Switches

Toggles and switches allow you to select and specify options that need to be determined before you
complete the function.
Click a toggle to alternate between two options.
Click a switch to display a list of options in a pop-up menu.
Reset button. This removes selection and back to empty value
Utility Menu
The Utility Menu is located on the left side of the graphics region and can be relocated by clicking on View
and selecting Tab Area. When Manufacturing Solutions and HyperForm working environments are loaded,
the Utility Menu is automatically switched to the HyperForm working environment. It provides tools for
defining/reviewing/editing a model. The Model tab option enables the Model Browser functionality
The user profile selection buttons are at the bottom of the menu.
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1Step
Quick access/switch to the Radioss One Step user profile
Radioss
Quick access/switch to the Incremental_Radioss user profile
Die
Quick access/switch to the Die Module user profile
Disp
Tools for visualization purpose
Util
Utilities to perform operations at geometry level.
User
User-created macros only
Dyna
Quick access/switch to Incremental_LsDyna user profile
To hide the Utility Menu:
From the View pull-down menu, uncheck the Utility Menu.
To display the Utility menu:
From the View pull-down menu, check the Utility Menu.
The menu bar

The menu bar, located just beneath the title bar, enable access to many types of functionality. Most menu
options access panels, but some options perform other tasks such as configuring the layout of the
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HyperForm environment.
When the HyperForm environment is loaded, the menu bar also enables you to access to the fundamental
menus regardless of the customization of the HyperForm interface.
Session 2: Using the online help

HyperForm includes a help system to provide information about using the interface. There are several
methods of accessing and using the online help system.
Method 1: Start online help from the pull-down menu

This method provides access to all information.
1.
Stay in the main menu; do not click any panel.
2.
From the Help menu, select HyperForm.

The HyperForm online help is launched.
This book contains all information including Release Notes, Users Guide, Reference Guide, Tutorials,
etc.
Method 2: Start context-sensitive help

This method allows you to search information specifically for individual panels.
1.
Click any panel from the main menu, for example, the Sections panel, and stay in the selected panel.
2.
From the keyboard, click the H key. This directly enters the help function for the selected panel.
The information for the Sections panel is displayed on screen.
Method 3: Finding information using the tabs

You can also search information by typing any keyword(s).
1.
Stay in the main menu; do not click any panel.
2.
From the Help menu, select HyperForm.
3.
Click on the Index or Find tab, and type in the desired keyword(s).
A list of related topics is displayed.
Session 3: File input and output

File input and output is performed through the File menu.
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File - Open/
Saves and retrieves HyperForm binary database files.
Save/ Save As
There are no restrictions placed on HyperForm database file extension names other
than those imposed by the operating system.
To load a HyperForm database file on top of another HyperForm database file (*.hf
), use the import option.
File - Import
Loads CAD generated geometry or finite element model information.

It is possible to import a CAD generated geometry or a finite element model
information file into a HyperForm database file.
HF PARM translator is used to import one step analysis ASCII input file
File - Export
Writes an ASCII file in a format specific to the selected analysis code.
Load
Load a the template file used to format the HyperForm database for a specific
analysis code, or load a Results file, or a Macro file
Run
Run a command file or a TCL script
Session 4: The concept of a collector

Collectors store entities, grouping together all the data pertaining to an entity and allowing you to handle the
data as a group. Collectors in HyperForm consist of the Components, Materials and Sections (for
Incremental_Radioss and Incremental_LsDyna analysis) panels.
The component and material collectors in HyperForm have specific data associated with them. In one-step
analysis, the component collector contains thickness data while the material collector holds the Youngs
Modulus of Elasticity value and other constants.
All entities in a HyperForm database are stored in collectors. Based on the analysis type, each collector
may use a dictionary or card image to define the attributes assigned to the collector.
The Collectors panel allows you to create and update collectors and assign and edit card images or
dictionaries. Before you build a model, create a component collector for storing or organizing different data.
Exercise 2: Understanding collectors and using online help

The Die_Mesh.hm file from Exercise 1 should still be loaded in HyperForm.
In steps 1 through 6, you will practice changing the visualization of component collectors.
1.
In the Model Browser, click on the Mesh

icon next to the Part component to turn off the display of
the mesh for that component. Notice the mesh of the Part component is no longer displayed in the
graphics area. The surface of the Part component is still visible.
2.
Click the Mesh icon to turn the mesh display back on.
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25
3.
Similarly, click the Geometry icon next to the various components to turn their display on and off. When
finished, right click on the Components folder and click Show to display all of the components
completely.
In steps 4 though 11, you will review card images, assign a new material to the Part component, and
use the online help.
4.
From the Application menu, select Incremental_Radioss.
5.
From the main menu, click the Components panel.
6.
Double-click component: and select Part.

The associated material is displayed. Notice material = Rigid_material.
7.
Click edit card to review the card image in solver definition.
8.
Click return to go back to the Components panel.
9.
Click material: and select CRDQ Steel material.
10. Click update. Notice the associated material is now changed to CRDQ Steel.
11. Press the H key to start the online help.
The online help is launched, displaying the help topic for the panel. Review information for the
Components panel. Return to the main menu when finished.
Session 5: Secondary Menu

The secondary menu contains several stand-alone functions, like calculating the distance between two
points. Accessing the secondary menu interrupts the active main panel and allows you to perform a function
from the secondary panel and then return to the main panel. For example, a user can access the secondary
menu by pressing the function keys, F1 through F12, Shift F1 through shift F12, and more.
Menu Items
The menu items on each panel allow you to specify settings and enter information that is needed to perform
the panels function. Panels can contain subpanels, function buttons, toggles, switches, entity selectors,
direction selectors, data entry fields, input fields, and pop-up menus.
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In the following discussion of menu items, you will be using the Translate panel. Access it from the
Geometry menu.
Entity Selector
The entity selector allows you to choose the type of entity to be modified when performing a function. The
entity selector may or may not have a switch
; some panels perform a function on only one type of entity.
The entity selector button is yellow; when it is surrounded by a blue box, the collector is active and ready for
you to select or pick the entities to be processed. You can click on the switch to change the entity selector
type.
Direction Selector
The direction selector allows you to define a plane or vector by using the global x, y, or z axis, or by
selecting a vector, or by selecting nodes in the database.
Direction selector pop-up menu

x-, y-, and z-axis Specify a direction along any one of the global axes.
vector
Use a pre-existing vector entity (something you can create using the vector panel) to
define a direction.
N1, N2, N3
Create a user-defined direction. Selecting two nodes, N1 and N2, allows you to define
a vector direction with base point at N1 toward N2. Selecting three nodes, N1, N2, and
N3, allows you to define a plane with base point at N1 (unless otherwise specified).
The vector is normal to the plane and its direction is determined by the right hand rule.
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Direction vectors for 2 point and 3 point definitions
Clears the node selections.
Reset
Input Fields
Input fields are used to enter text or numerical values. A description of the type of input precedes the field.
For numeric input fields, you can use the keyboard to enter the value or double-click the input field and use
the pop-up calculator to enter the value.
An example to input values and operations is as below:

"0.0 (default) + 6" will need to be inputted as 0.0(default), 6, +, enter
Pop-up Menus
Pop-up menus display when there are several options from which to choose.
For example, the extended entity selection menu (shown below) allows you to specify alternate methods for
selecting entities of the current data type. To use the extended entity selection menu, click the yellow data
type button of the entity selector. The menu automatically closes when you have made your selection.
Notice the grayed-out options within the pop-up menu indicates that the function is disabled in the selected
entity selection menu.
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Function Buttons
The color of the menu button corresponds to its purpose:
Green
Carries out a function or a command.
Red
Exits a panel or aborts a command.
Exercise 3: Translating Elements

The Die_Mesh.hm file from the previous exercise should still be loaded in HyperForm.
Access the Translate panel by hot keys

1.
From the Geometry menu, select Translate.
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All selections under the Translate option are displayed. SHIFT + F4 is the hot key for the Translate
function.
2.
Press SHIFT + F4 to access the Translate panel directly.
Select the elements to translate

1.
Click the entity selector switch
A pop-up menu is displayed, listing all the entity types that can be modified with the Translate panel.
The mouse cursor is located at the center of the pop-up menu.
2.
Select elems to specify "elements" as the entity type you want to translate.
After you select elems, the pop-up menu automatically closes. The yellow entity selector button
displays "elems" and the button has a blue border to indicate that it is active.
3.
Click elems.
The extended entity selection menu displays, with the mouse cursor in the center.
4.
Select by collector to indicate you want to select the elements by component collector.
After you select by collector, a list of component collectors is displayed.
5.
In the graphics area, pick a cyan element by clicking near its element handle (the dot in the center of the
element). Selecting this element also selects the component collector containing the element, Part in
this case.
The element picked is momentarily highlighted white. The check box preceding Part has a white check
mark in it.
6.
Click select to select all the elements in the component collector, Part, as the elements to be modified
when you use the translate function.
The Translate panel again displays and all of the elements in the Part component are highlighted.
Specify a direction to translate the selected elements

1.
Click the direction selector switch.

A menu is displayed with a list of plane and vector options for translating the selected entities. The
mouse cursor is located at the center of the pop-up menu.
2.
Click N1 N2 N3 to select the N1, N2, N3 method.

After you select N1, N2, N3, the pop-up menu automatically closes.
3.
Click N1.
The blue border around N1 indicates it is active. The selected elements in the graphics area are now gray
because the entity selector is not active.
4.
In the graphics area, pick a node.

A green circle displays in the graphics area at the node that was picked. The N1 button no longer has a
blue border, but the N2 button does. N2 is currently active.
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5.
In the graphics area, pick any other node.

A blue circle displays in the graphics area at the node you specified. The N2 button no longer has a blue
border, but the N3 button does. N3 is currently active, but in this case, a node for N3 will not be
specified.
6.
In the graphics area, right click the blue circle to deselect the node N2.
The blue node N2 is not displayed in the graphics area. The N2 button now has a blue border.
7.
In the graphics area, pick a different node. This new node is the new N2 node.
A blue circle displays in the graphics area at the node you specified.
Specify a distance to translate the selected elements

1.
Double-click magnitude =.
The calculator pop-up menu appears.
2.
Input 50.0, click enter and click exit to leave the calculator.
3.
Click translate +.
The highlighted elements move 50 units in the positive N1-N2 vector direction with N1 being the vectors
base node and the vector passing through N2.
4.
Click reject to reject the translation action.
5.
Click f on the permanent menu. The model is resized to fit the screen.
Session 6: Default HyperForm Files

HyperForm includes or automatically creates several default files. These include:
hm.cfg
configuration file
hmmenu.set user interface settings

command.
cmf
command file
hm.cfg
The hm.cfg file is a default configuration file read on start-up. The hm.cfg file controls many aspects of
how HyperForm runs at your particular site. You can edit the commands in the hm.cfg file to your own
preferences.
command.cmf
The command.cmf file is a standard ASCII file that HyperForm reads and writes. Command files allow you
to retrieve a work session in case of a system crash or program a series of procedures. You can use a
command file in applications that contain repetitive steps or you can create demonstrations.
All commands executed by the HyperForm command processor are written to this file. This file is
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automatically created in the directory in which you started HyperForm. If the file already exists, new
commands are appended to the existing file.
For more information about the command.cmf file, please see the HyperForm online help topic HyperForm
Commands.
hmmenu.set
The hmmenu.set file is a binary file that HyperForm updates when you exit HyperForm. Your personal
hmmenu.set file stores many global parameters and is located in the directory from which you started
HyperForm. If the file already exists, it is overwritten after you run a new session. The most recent global
parameter values in the current HyperForm session are written to this file when you exit. The next time you
start HyperForm, it has the values recorded in the hmmenu.set file. If the file does not exist when
HyperForm is invoked, the global parameter values are default values.
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Radioss One Step

The following Radioss One Step tutorials are available:

HF-1000: One Step Stamping Simulation
HF-1040: Laser Weld
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This tutorial describes the steps required for modeling and running one step analysis that can be performed
in HyperForm within the Radioss One Step user profile.
The following steps are involved in one step analysis:
1.
Geometry cleanup and meshing
2.
Assigning materials and thickness
3.
Defining symmetry
4.
Defining blankholders
5.
Defining drawbeads
6.
Setting the stamping direction either by tipping the part or by using the existing part orientation as the
forming axis
7.
Checking for undercuts
8.
Running the analysis
Exercise 1: Geometry Cleanup and Meshing

This exercise uses the model file Part1a.igs. The following image shows the program with the Radioss
One Step user profile and model file loaded:
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1.
Click File > Import....
2.
Click the Import Geometry icon
3.
Click the Select Files icon

and browse to the file
<installation_directory>\tutorials\mfs\hf\1Step\part1a.igs.
4.
Click Import and then click Close.
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Step 2: Geometry cleanup

1.
In the OneStep tab, right-click on Parts > New > Pick... as shown in the image below:
Note: The component name is recognized automatically as Part once the model is loaded into the
session.
2.
Pick the part from the screen.
3.
Click on proceed.
Note: The material CRDQ steel and a thickness of 1 mm is assigned to the part by default.
4.
Right-click on the part lvl1 and select Geometry > Remove Holes.
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5.
In the diameter< field, enter 40.
6.
Click on the yellow surfs button to highlight it. Click again and select displayed from the extended entity
selection menu. This selects all the entities on the screen.
7.
Click find. All pinholes found are highlighted with xP.
8.
Click delete to close the hole.
9.
Click return to close the panel.
Step 3: Meshing the part

1.
Right-click on the part lvl1 and select Mesh > R-Mesh.
2.
Enter the values as shown below:
3.
Click on Mesh....
4.
Click surfs and select displayed from the extended entity selection menu. This selects all the surfaces
displayed on the screen.
5.
Click proceed.
6.
Click Close.
Exercise 2: Setting up One Step Analysis
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Step 1: Assigning the material and thickness to the part

1.
Right-click on CRDQ Steel > Database... to change the material selection.

Note: A user-defined material can also be added to the database by editing the material file hf.dat.
2.
When finished viewing/changing the material selection, click Close to close the dialog.
3.
Highlight Thickness:1 by clicking on it once. Double-click on the digit 1 to make it editable and change
the value to 1.5.
Step 2: Setting symmetry conditions

1.
In the OneStep tab, right-click on Symmetry:No > Edit.
2.
Click on the yellow nodes button and select on plane from the extended entity selection menu.
3.
Click the toggle switch to x axis.
4.
Pick a point on the symmetric plane, as shown below.
5.
Click select entities.
6.
Under Constraint Type, click the X radio button.
7.
Click size = and enter 10.
8.
Click update.
9.
Click return.
constraints along the symmetric edge
Step 3: Setting the stamping direction
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1.
Right click on Stamping Direction:X and select Z.

Note: Stamping can also be done in any of the three principal axes or an arbitrary axis in space by
using Stamping Direction in the Autotip panel. Use the stamping direction subpanel to specify the
stamping in an arbitrary direction.
In the Autotip panel, use the vector selector switch to assign a direction. If the stamping direction of
the part is not one of the principal axes, use N1, N2, N3 option and select 2 nodes on the model to
define a direction.
Click set.
Step 4: Selecting the blankholder

Blankholders can be defined as the upper and lower holding surfaces that control metal flow around a shape
to be formed in a draw operation. They supply a restraining force on the material during the pressing
process.
HyperForm allows you to define the blankholder force in two ways: on element and on edge. The correlation
between the magnitude and level of the applied forces is always available. Edge blankholder force application
allows you to restrain an edge by enabling automatic selection of all nodes between two user-defined nodes
along a free edge of a part.
You can define the blankholder force in two ways: tonnage force or pressure level (high, medium and low).
Note
The pressure level is proportional to the area of blank under the blankholder as well as thickness.
A pressure level of 2MPa, 5MPa and 10MPa for a 1mm blank has been chosen as a reference for
Low, Medium, and High (based on practical experience). The tonnage (metric ton unit) is equivalent
to the pressure times the blankholder area normalized/scaled by the thickness (1 metric ton =
9810N).
1.
In the OneStep tab, right click on Blankholders > New. If desired, you can double click on
Blankholder1 to change the name.
2.
Right click on Blankholder1 > Elements
3.
Click elems and select on plane.
4.
Select z-axis and pick a node on the binder (flat region) for B (base node).
5.
Click proceed.
6.
Friction, Tonnage and Pressure level appears below Blankholder1. Double click on the values for
Friction and Tonnage to change the values.
7.
Right click on Pressure Level: and select Medium.

Notice that the Tonnage changes according to the selected pressure level.
Step 5: Creating drawbeads

Modeling the exact drawbead geometry requires a large number of elements, which increases CPU time
dramatically. A practical approach is to use an equivalent drawbead model by representing the drawbead
analytically and providing a constant drawbead restraining force and closure force.
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Use the calculate subpanel to determine the closure and restraining force based on drawbead dimensions.
The restraining force is the value of the force (per unit length) applied by the bead in the plane of the blank
surface. The closure force is the force (per unit length) required in the perpendicular direction to keep the
drawbead closed.
1.
From the OneStep tab, right-click on Drawbeads > New > Restrain.
2.
Pick two nodes on the part as indicated in the image below to define the drawbeads.
3.
Click create.
Notice a message shows "The drawbead set has been created." A line representing drawbeads is
created.
4.
Notice that Drawbead1 is created with a default Restraint Force and Pressure Level. Double click
Drawbead1 to rename it.
5.
Right click on Pressure Level > Medium. Notice that Restraint Force changes based on the Pressure
Level selection.
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Step 6: Tipping
1.
Right click on the OneStep tab anywhere in the red box as shown below and select Autotip.
2.
Select the autotip radio button.
3.
Verify the entity selector is set to comps and select the lvl1 component.
4.
Verify the toggle is set to full model and keep the rest of the options as default.
5.
Click calc autotip.

Notice the angle to be tilted is displayed on the header bar on the left hand bottom corner and the
magnitude is displayed in the angle field
6.
Click autotip.
7.
This action will tilt the part by an angle calculated by HyperForm to reduce draw depth during forming.
8.
Click return.
Step 7: Checking for undercuts

1.
42
Right click on the OneStep tab anywhere in the red box as shown above and select Undercut Check.

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2.
Click on the yellow comps button to highlight it.
3.
Pick the part from the screen.
4.
Click on check undercut.

Notice the message 0 elements with undercut detected. If there are undercuts in the model then the
failed elements are highlighted on the screen.
5.
Click return.
Step 8: Checking the model and running the analysis

1.
Right click on the OneStep tab anywhere in the red box as shown above and select Check Model. A
message is displayed on the message bar, stating Model checked.
2.
Right click on the OneStep tab and select Run.
3.
Enter a name for the run.

The feasibility solver launches, as shown below:
Note: It is advised to run the analysis into a separate folder.
Exercise 3: Post processing

After the successful completion of the run, right click on the white space of the OneStep tab to see the
Blank Shape, %thinning and Formability options, which were not available before running the analysis.
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Right click and select the desired result type for post processing.
Step 1: Blank Shape

1.
Right click on the OneStep tab anywhere in the white space and select Blank Shape.
2.
Under Blank Shape Profile: click on the Initial radio button. Notice that the initial blank shape is
displayed on the screen, as shown below.
3.
Click on export to write out an iges boundary of the predicted blank shape to the folder where feasibility
analysis was run. The file will be named as <filename>_blank.iges.
Exercise 4: Blank Fit
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Step 1: Fitting the initial blank shape into different configurations

1.
From the Tools menu, click on Blank Fit. This will bring up the blank fit utility, as shown below:
2.
Use the Part drop down menu to select the component on which the one step analysis was run.
3.
Keep the default values for Density and Cost per Kg.
4.
Under PLOT OPTIONS, click on the checkbox next to %Thinning and Formability. Notice that %
Thinning and Formability buttons becomes active.
5.
Rotate the model to a desired direction and click on %Thinning. This contours the model with %
Thinning result type.
6.
Left click to capture the image to include it in the report. A right click will abort the function and return to
the Blank Fit macro. This is indicated by the image on the right hand bottom corner of the graphics area
.
7.
Under BLANK SHAPES, check all the boxes.
8.
Click on Blank Fit.

This will fit the blank into the selected shapes.
9.
Click on Publish Report.

This will open a HTML report with hyperlinks to blank shapes and results, as shown below.
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11. Click Close.
Exercise 5: Blank Nest

Step 1: Nesting the initial blank shape on coil or sheet
1.
Click Tools > Blank Nesting.
2.
Click on elems and select displayed from the extended entity selector menu.
3.
Click on the nesting button. A new window called Blank Nesting opens which allows you to nest the
blank in different configurations.
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4.
Right click any where on the blank shape and select Duplicate. This will create a duplicate of the
existing blank shape.
5.
Right click anywhere on the blue screen and select Auto nesting from the menu. This will make the
best fit of the 2 shapes of the blank on a sheet.
6.
Click on File > Export.
7.
Enter a name and click on Save. This saves an .iges boundary of the nested sheet.
8.
Select File > Exit to close Blank Nesting,

Note: There is a detailed explanation of all the options in Blank Nesting in the HyperForm online help.
Exercise 6: Report Generation

Step 1: Publishing a report of the feasibility analysis results
1.
Click Tools > Report Generator. The Report Generator opens up as shown below:
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2.
Click on the Result File: file browser icon and select <filename>.res in the folder where you have
run the feasibility analysis.
Note: You must run feasibility analysis in a separate folder with no spaces in the path and in the folder
name.
3.
Click on the Report Name: file browser icon and type a name for the report.
Note: The folder and report name must not have any spaces in the folder name or file name.
4.
Check all the boxes under Result Types.
5.
Under Export Mode, select HTML.
6.
Under Export Options, select JPEG.
7.
Click on Generate. This creates a report in the folder selected in the Report Name field. It includes a
folder called <filename>_data_dir and <filename>.hml.
8.
Open the folder that was selected for Report Name. Open the file <filename>.html in Internet
Explorer or Firefox. This opens a html page with hyperlinks to the selected result types and the
corresponding image with contour, as shown below:
9.
Click Close to close the panel.
Return to Radioss One Step Tutorials
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When designers create CAD geometry, their priorities are different from those of analysts trying to use the
data. A single smooth surface is typically split into smaller patches, each a separate mathematical face.
The juncture between two surfaces often contains gaps, overlaps, or other misalignments.
To make the geometry more appropriate for meshing, analysts need to combine a number of faces into a
single smooth surface. A single, smooth surface not only allows the elements to be created on the entire
region at once, but also prevents unnecessary artificial or accidental edges from being present in the final
mesh.
Sometimes, the gaps, overlaps, and misalignments present when surface data is imported can affect the
mesh quality. By eliminating misalignments and holes, and suppressing boundaries between adjacent
surfaces and unnecessary details, you can automesh across larger, more logical regions of the model and
improve the overall meshing speed and quality.
In this tutorial, you will use a variety of tools to prepare surface geometry for meshing.
Exercise 1: Reviewing Geometric Problems
Exercise 2: Fixing Geometric Problems
Tools
Auto Cleanup panel
The Auto Cleanup panel performs automatic geometry cleanup
Quick Edit panel (F11 hotkey)

This panel combines many tools for rapid editing of model geometry.
Exercise 1: Reviewing geometric problems

In this exercise, you will first review a variety of common geometric problems after reading a CAD file. The
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solutions are discussed in Exercise 2.

This exercise uses the model file Bpillar_cleanup.hf.

1.
Click File > Open....
2.
Browse to the location <Installation Folder>\tutorials\mfs\hf\1Step and select the

Bpillar_cleanup.hf file.
3.
Click Open.
Step 2: Review the model in Topology color mode

1.
Click View > Toolbars > Visualization to display the Visualization toolbar. The Visualization toolbar will
need the panels displayed also in the View menu.
2.
From the toolbar, select Geometry Color Mode
and change to By Topo.
Notice the color of the model is changed and topology definitions are displayed on screen.
3.
From the toolbar, click Shaded Geometry & Surface Edges
icon to shade the surfaces on screen.
The model comes in with several geometric problems after importing. You will first review the problems to
have a better understanding of the nature of the model.
In Topology color mode, each color represents different topological modes:
Free edge (Red color): The edge is owned by one surface. On a clean model, free edges appear only
along the outer perimeter of the part and internal holes. Free edges that appear between two adjacent
surfaces indicate the existence of a gap between the two surfaces.
Shared edge (Green color): The edge is owned by two adjacent surfaces. When the edges between
two adjacent surfaces are shared (green), there is no gap or overlap between the two surfaces, and they
are geometrically continuous. The automesh utility always places seed nodes along their length and will
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produce a continuous mesh without any gaps along that edge. The automesh utility will not construct
any individual elements that cross over a shared edge.
Suppressed edge (Blue color): The edge is owned and shared by two adjacent surfaces but it is ignored
by the automesh utility. They are blue dotted lines by default. Like a shared edge, a suppressed edge
indicates geometric continuity between two surfaces but, unlike a shared edge, the automesh utility will
mesh across a suppressed edge as if were not even there. The automesh utility does not place seed
nodes along their length and, consequently, individual elements will span across it. By suppressing
undesirable edges you are effectively combining surfaces into larger logical meshable regions.
Non-manifold edge (Yellow color): The edge is owned by three or more surfaces. They typically occur
at "T" intersections between surfaces or when 2 or more duplicate surfaces exist. The automesh utility
always places seed nodes along their length and will produce a continuous mesh without any gaps along
that edge. The automesh utility will not construct any individual elements that cross over a nonmanifold
edge. These edges cannot be suppressed and can sometimes be indication for duplicated geometry.
Step 3: Review and measure the largest pinhole diameter

1.
From the toolbar, select the Visualization icon
2.
From the Visualization tab, select the Topology icon

Non-manifold check boxes.
.
and clear the Shared, Suppressed and
Only the red free edges display.

3.
Click Close to close the Visualization tab.
4.
Press T on your keyboard and input thetax = -101.154, thetay = -59.845 and thetaz = 109.363.
5.
Click set angles to set the true view.
6.
Notice several pinholes as shown in image below.
Notice the biggest pinhole as indicated in the left side of the image is considered as a part of the feature
and will be kept. The smaller holes on the flange area are considered removable.
7.
Press F4 on the keyboard to go to the Distance panel.
8.
Hold the Ctrl key and middle mouse button to draw a circle to zoom in the center bigger pinhole on the
flange as indicated in the image below.
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9.
In the Distance panel, select the two nodes option. Notice a halo is surrounding N1.
10. Hold the left mouse button and move the mouse cursor to the N1 location on top of the hole (location A
in the image) until the hole is highlighted. Release the left mouse button and click again to create a temp
green node created on top of the hole.
11. Repeat the same procedure for N2 to create a second blue temp node as shown as location B in the
image.
12. Notice the diameter of the hole (value next to distance = ) is about 3.2.
The approximate diameter of the largest hole is about 3.2. Remember this value so you can apply it
when you remove pinholes later.
13. Press F on the keyboard to fit the model to the screen.
14. Click return to close the panel.
Step 4: Review free edges

1.
From the toolbar, select the Wireframe Geometry icon
2.
Notice several red lines as shown as in the image below. An example can be found as indicated where
an arrow is pointing.
Free edges that appear between two adjacent surfaces indicate the existence of a gap between the two
surfaces.
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Step 5: Review a missing surface

1.
From the toolbar, select Shaded geometry and surface edges
The surfaces are shaded on the screen.

2.
3.
From the Visualization tab, select the Topology icon

manifold to turn on the display of all definitions.
4.
Click v on the keyboard to open the dialog with saved views.
5.
Click restore 1 to display the previously saved missing surf view.
6.
Notice the missing surface as shown in the image below.
.
and check Shared, Suppressed and Non-
Step 6: Review the distorted surface

1.
2.
Click restore 2 to display the previously saved distorted surf view.

Notice the dark shadow on top of the surface as indicated in the image below.
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You will use the Automesh panel to verify the quality of the surface in the following procedures.
3.
Click Mesh > Auto Mesh.
4.
Click surfs and select only the surface with dark shadow.
Notice two surfaces are selected as shown in the image below. This is a first indication of distorted
surface.
5.
Click element size = and input 0.5.
6.
Click mesh.
Notice the mesh pattern has poor quality and higher node density at the center area (along the center
shared edge). This is a second indication of the distorted surface.
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7.
Click abort to abort the meshing operation.
8.
Step 7: Review the duplicated surface

In this model, you have duplicated surfaces existing in this model.
1.
2.
Click front to review the front view.

Notice the yellow lines surrounding the surface as indicated by an arrow below:
3.
Click Geometry > Defeature and then select the duplicates subpanel.
4.
Click the switch and change to faces.
5.
Click find.
Notice the two surfaces are highlighted and identified.
Step 8: Review deviated trim line

1.
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2.
Click restore 3 to display the previously saved improve share view.

Notice the deviation of one trim line as circled in the image below. The deviation of the trim lines could
cause poor mesh quality. An ideal trim line will look like the dash line on the right hand side of the image
below. You will correct this problem later.
Step 9: Review incorrect fixed point definition

1.
2.
Click restore 4 to display the previously saved fixed point view.

Notice the incorrect definition for the free boundary. This is due to the incorrect definition of the fixed
point as indicated in the image below.
Exercise 2: Fixing geometric problems

In this exercise, you will use a variety of tools to fix the geometric problems.
Step 10: Remove pinholes using the Auto Cleanup panel
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1.
From the Geometry menu, select Auto Cleanup.
2.
Click edit parameters to launch the Parameters File editor to modify Auto Cleanup settings.
3.
In the Parameters File editor, clear all settings under Other options:
4.
Click the
5.
Repeat the steps above and disable all options EXCEPT Geometry cleanup and Surface hole
recognition.
6.
Click
7.
In the first row under Surface hole recognition, input 4.0 under R< and check the Remove option. The
final result should look like the image below. Since the largest diameter of the holes on the flange is
about 3.2, using the value 4.0 can make sure all the holes on the flange will be removed.
8.
Change Target element size: to 3.0.
next to Other options and change to . This disables the other options.
(Delete line) to delete the second row under Surface hole recognition.
The target element size is the desired mesh size after geometry cleanup.
9.
Click Apply and Ok to return to the Auto Cleanup panel.
10. Click surfs and select all from the pop-up window.
11. Click autocleanup.
Notice the cleanup process is launched. A message is displayed "There is a conflict between the user
requested element size of 3 and the quality criteria ideal element size 0.5 used in the optimization, How
do you wish to proceed?"
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12. Click Continue.

When the cleanup process is finished, a message "Geometry cleanup process is finished" is displayed
in message bar. After the auto cleanup process, notice that:
The four holes on the flange are removed.
The number of free edges (red edges) is reduced as shown in the image below. If you wish to see
only the free edge definitions, select the Visualization
definitions EXCEPT Free edges.
icon and deactivate all topologic
Duplicate surfaces are removed.
13. Click return to close the Auto Cleanup panel.
Step 11: Fix the missing surface using the Quick Edit panel
In this step, you will manually clean up geometry using Quick edit panel.
1.
From the toolbar, select the Visualization
2.
From the toolbar, click the Shaded Geometry & Surface edges icon
3.
4.
Click restore 1 to withdraw previously saved missing surf view.
5.
Click F11 to access the Quick Edit panel.
6.
Click the line(s) button right next to filler surf:.
icon and activate all topologic definitions.

to shade surfaces.
A blue halo appears and surrounds the line button.

7.
Click any red edge of the missing rectangular surface. A surface is created to fill the missing surface.
Notice the previous four free edges are now changed to a green shared edge.
8.
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Step 12: (optional) Delete the distorted surface and recreate it

Using the Auto Cleanup function, most of the time, distorted surfaces are removed automatically. If you
don't see distorted surfaces after the Auto Cleanup operation, skip this step.
1.
2.
Click restore 2 to display the previously saved distorted surf view.
3.
Press F2 on the keyboard to go to the delete panel.
4.
Click the entity selector and change it to surfs.
5.
Click surfs and select the distorted surface (the surface with dark shadow) from the screen.
6.
Click delete entity. This action deletes the distorted surface.
7.
From the menu bar, click Geometry > Create > Surfaces > Ruled.
8.
If necessary, click the switch to set the selection to line list. Click the upper line list selector and
select the three red edges as shown in the image below.
9.
Click the lower line list selector and select the one red edge as shown in the image below.
10. Verify that auto reverse is activated.

11. Click create.
12. Click return.
Notice a new surface is created at the same location. The new surface has three shared (green) edges
and one free (red) edge as indicated in the image below.
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13. Press the F11 key to open the quick edit panel.
14. Click the line(s) button right next to toggle edge:.
15. Change the tolerance to be 0.1. This is the geometric cleanup tolerance.
16. Use the left mouse button to click the red free edge to turn it into a shared green edge.
Step 13: (optional) Delete the duplicated surfaces

Using the Auto Cleanup function, most of the time, duplicated surfaces are removed automatically. This
step is optional if you wish to remove duplicated surfaces manually without Auto Cleanup. If you dont see
duplicated surfaces after the Auto Cleanup operation, skip this step.
1.
Click Geometry > Defeature.
2.
Select the duplicates subpanel.
3.
Change the entity selector from surfs to faces.
4.
Click faces and select all from the pop-up window.
5.
Click find. Notice two duplicated surfaces are highlighted and identified.
6.
Click delete to remove the duplicated surfaces.
7.
8.
From the Visualization tab, select the Topology icon and uncheck Shared, Suppressed and Nonmanifold to turn off the display of all definitions EXCEPT free edge (red line).
9.
From the toolbar, select the Wireframe Geometry icon
Notice a red circular line indicating free edge. Since there is no hole existing, it indicates a problem with
redundant surface.
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10. From the toolbar, click the Shaded Geometry & Surface edges icon
to shade surfaces.
11. Press F2 on the keyboard to go to the Delete panel.

12. Change the entity selector to surfs.
13. Hold the left mouse button and move the cursor to the red circular line until the circular surface edge is
highlighted. Let go of the left mouse button and click delete entity to delete the surface. Refer to the
image below.

15. From the toolbar, select the Visualization icon
16. Check Shared, Suppressed and Non-manifold to turn on the display of all definitions.
Step 14: (optional) Relocate a shared edge

Using the Auto Cleanup function should have relocated this edge. If you don't see this edge after the Auto
Cleanup operation, skip this step.
1.
2.
Click restore 3 to display the previously saved improve share view.
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3.
Click F11 to access the Quick edit panel.
4.
Click the points panel right next to replace points:. The function is activated.
5.
Click points and click the fixed point B as shown in the image below
6.
Click retain and click the fixed point A as shown in the image below.
Notice the two fixed points are now merged. Point B is moved to point A.
7.
Repeat steps 5 and 6 to merge point C and point D by moving point D to the location of point C.
Step 15: Fix the incorrect fixed point

1.
2.
Click restore 4 to display the previously saved fixed point view.
3.
Click point(s) for release point to activate this feature.
4.
Click the fixed point as indicated in the image below.
Notice the fixed point is released and some free edges are generated.
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5.
Step 16: Merge the two free edges

In the following steps, you will switch two free edges by replacing one free edge with the other free edge.
1.
Click Geometry > Edit > Surface Edges > Replace.
2.
Click line under moved edge : and select the line shown as B in the image.
3.
Click line under retained edge : and select the line shown as A in the image.
4.
Click cleanup tol = and input 1.0.
5.
Click replace. Notice the gap is closed and a new share edge is generated.
Step 17: Toggle the remaining red edges into shared edges and un-suppress two
blue edges
You are still in the edit surface edges panel.
1.
Click toggle subpanel.
2.
With a blue halo surrounding the edge button, click the two free edges as indicated in the image below.
3.
Notice the two red free edges are now converted into shared edges.
4.
Press the t key and input thetax = 145.968, thetay = -79.495 and thetaz = 30.150.
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5.
Click set angles to set the true view.

Notice three blue suppressed edges are indicated in the image below. You will toggle the blue
suppressed edges and turn these two suppressed edges to green shared edges.
6.
Click return to go back to the edit surface edges panel.
7.
With the edge button activated, right-click the two suppressed edges to change them to green shared
edges.
Step 18: Save the cleanup result

1.
From the File menu, click Save As.
2.
Use the file browser to save the file as Bpillar_cleanup_complete.hf.
3.
Click save.
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In this tutorial, you are introduced to the meshing capabilities provided in HyperForm.
Several meshing tools are available:
BatchMesher
AutoMesh
R-Mesh (available in Radioss One Step, Incremental_LsDyna and Incremental_Radioss user profiles)
B-Mesh (only available in the Incremental_Radioss and Incremental_LsDyna user profiles)
The BatchMesher is an external tool that can perform geometry feature recognition, cleanup and automatic
meshing (in batch mode) for given CAD files without user interaction. Detail of the BatchMesher will not be
discussed in this tutorial. Refer to the HyperWorks online help for more information about BatchMesher. In
this tutorial, you will be introduced to the three meshing modules: AutoMesh, R-Mesh and B-Mesh.
In HyperForm, most of the element creation panels use the AutoMesh module, which supplies as much
automated assistance as possible. AutoMesh allow you to adjust mesh interactively with a wide variety of
parameters and choose from a suite of algorithms. You can interactively control the number of elements on
each edge or side and you can immediately determine the nodes that are used to create the mesh. You can
adjust the node biasing on each edge to force more elements to be created near one end than near the other,
which allows you to see immediately the locations of the new nodes. The new elements can be specified as
quads, trias, or mixed and can be first or second order elements. The created mesh can be previewed, which
allows you to evaluate it for element quality before choosing to store it in the HyperMesh database. While
you are in the meshing module, you can use any of viewing tools on the visual options menu to simplify the
visualization of complex structures in your model. You can also re-mesh existing meshing interactively or
automatically on surfaces or groups of elements. You will learn to use a variety of AutoMesh features later in
this tutorial.
R-Mesh (Rigid tool surface mesh) allows you to quickly mesh a rigid tool surface by specifying the max
length of element, minimum length of element, chordal deviation, and fillet angle.
B-Mesh (Blank surface mesh) allows you to quickly mesh a blank component. You can specify an average
edge length and mesh selected surfaces. B-mesh is discussed in incremental analysis tutorials.
Tools
The tools in this tutorial can be found in the Radioss One Step user profile.
Midsurface
The Midsurface panel allows you to extract the midsurface representation of a solid part.
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AutoMesh
The AutoMesh panel allows you to create meshes or re-mesh existing meshing.
R-mesh macro
Rapidly generates a quad/tria shell mesh ideal for representing rigid tool surfaces.
Exercise: Automeshing with different meshing options

This exercise uses the model files Bpillar_AutoMesh.hf, Bpillar_AutoMesh_remesh.hf and
Bpillar_AutoMesh_remesh_final.hf.

1.
From the File menu, select Open....
2.
Browse to the file

<installation_directory>\tutorials\mfs\hf\1Step\Bpillar_AutoMesh.hf.
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3.
Click Open.
Step 2: Retrieve the mid-surface

1.
From the visualization toolbar, select the Geometry Color Mode icon
and change to By Topo.
2.
From the toolbar, click Shaded Geometry & Surface Edges
to shade the surfaces on screen.
The model is a pre-cleanup geometric model with thickness. In reality, it is common to have CAD data
with thickness. You will learn how to extract midsurface in the next steps.
3.
From the menu bar, click Geometry > Midsurface.
4.
Verify that the auto midsurface subpanel is selected. The default toggle is set to closed solid.
5.
Click extraction options.
6.
Input max thickness ratio = 2.0 and toggle extract by component to cross components.
7.
Click return to exit the extraction options panel and return to the Midsurface panel.
8.
With surfs activated, graphically pick a surface on screen.

Notice all surfaces are selected and highlighted.
9.
Click extract.
Midsurface extraction takes about one to four minutes depending on system performance. Notice that
once the operation is finished, a new component named Middle Surface is created that contains the
extracted midsurface. By default, HyperForm applies the transparent view to the generated midsurface.
10. Click return to exit the panel.
Step 3: Prepare AutoMesh

1.
Using the Model Browser, expand the Components folder and hide all geometry EXCEPT Middle
Surface.
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2.
Right-click on automesh. In the menu that appears, select Make Current. This sets the automesh
component as default working component.
3.
From the File menu, select Save As... and enter the file name as automesh_ready.hf.
4.
Click Save.
Step 4: AutoMesh size, biasing and automeshing secondary panel

In this step, you will learn how to interactively mesh a blank using size and biasing control. The size and
bias subpanel allows you to mesh surfaces or re-mesh existing meshes with some control over how the
mesh is created. You can also adjust a mesh on-the-fly during the creation process using this subpanel.
1.
2.
Verify that the size and bias subpanel is selected.
3.
Click surfs and select displayed from the pop-up menu.
4.
Verify the following settings:

element size = 3.0
mesh type = mixed
elems to current comp toggle is set (generated elements will be stored in the current working
component automesh component)
first order toggle is set
next to map: the size and skew checkboxes should be selected
Toggle is set to interactive
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5.
Click mesh.
Notice a mesh is displayed in the graphics area. You have entered the automeshing secondary panel
(inactive mesh module), which allows you to manually adjust mesh before it is finalized.
6.
With the density subpanel selected and the adjust: edge option activated, move the mouse cursor onto
any edge density number in the graphics area, and left-click to increase edge density.
7.
After the edge density number is modified, click mesh again to preview the modified mesh.
Refer to the following images:
Notes:
adjust: edge allows you to interactively increase/decrease mesh edge density by right/left-click.
calculate: edge allows you to interactively modify individual edge or all edges based on desired element
size.
set: allows you to interactively modify individual edges or all edges based on a specified value.
8.
Select the mesh style subpanel.

Mesh style allows you to specify the meshing and smoothing algorithm to use for each face of each
domain when you are following a surface-based approach to the automeshing secondary panel.
9.
Under elem type: click the selector
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69
10. Click the set all button above the

screen.
button and press the P key to refresh the
Notice all the element type symbols are changed to tria. Refer to the image below.
11. Click mesh.

Notice the mesh type and symbol is changed to trias.
12. Click reject to reject the mesh.

13. For meshing algorithm, autodecide is the default algorithm. Review the image below for all the mapping
definitions.
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14. Under elem type: click the selector
and select mixed element type
15. Click set all above the mixed button.

16. Click mesh again.
17. Select the biasing subpanel.
Biasing allows you to control the element density biasing along edges. Element biasing is the placing of
elements along an edge so that element size is smaller at one end than at the other, and is one way to
improve element quality when doing transitioning.
By default, all mesh edge biasing is linear with value 0.0. You can change the biasing style and
increase/decrease biasing factor by left/right clicking on the edge biasing numbers.
The following image shows different biasing styles.
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18. Select the checks subpanel.

The checks option enables you to check the quality of generated elements before they are generated.
19. Click jacobian.
Notice the default Jacobian value is 0.7. Elements with a Jacobian value < 0.7 are displayed in red in the
graphics area. This option enables you to quickly identify initial quality before accepting the mesh.
20. Click return twice to close the panels.
21. From the File menu, select Save As... and enter the file name as automesh_size.hf.
22. Click Save.
Step 5: AutoMesh QI optimized

In QI optimized meshing, the surfaces are meshed to optimize the quality index (QI) of the elements
generated. You can either provide a criteria file or update the quality index panel with the desired quality
criteria. The surfaces are then meshed with algorithms that produce the best quality index. The placement of
the nodes on the surface is also optimized to improve the QI.
1.
Click File > Open.
2.
Browse to select the previously saved automesh_ready.hf file and click Open.
3.
4.
Select the QI optimize subpanel.
5.
Input element size = 3.0.
6.
Click edit criteria.
7.
Set up all the criteria as shown in the following image:
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Note: It is recommended that you follow these guidelines for better accuracy:
Warpage should be less than 25
Chordal Deviation should be small. 0.9 is a good threshold value to start with.
Larger Jacobian values are better. Eliminate negative Jacobian values to prevent solver crashes. 0.4
is a good threshold value.
Chordal Deviation should be selected, with a small value (0.9)
8.
Click Apply and OK to close the Criteria File Editor.
9.
You are still in the QI optimize subpanel. Uncheck smooth across common edges with.
This step disables the smoothing operation of mesh across minor changes in surface angles.
10. Click the surfs button and select displayed.

11. While all displayed surfaces are highlighted and selected, click mesh.
12. Click return to accept the mesh.
13. Click File > Save As... and enter the file name as automesh_QI.hf.
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14. Click Save.
Step 6: AutoMesh edge deviation

The edge deviation subpanel allows you to set specific meshing parameters to limit how far the mesh
elements can deviate from the actual edges of the surfaces meshed.
The edge deviation normally occurs on curved edges, because individual elements have straight edges and
therefore can only approximate a curve. This automesh sub function automatically chooses the best element
size to approximate a curve, within limits that you specify. Note that this differs from the size and bias sub
panel, which only meshes with elements of a uniform size that you specify.
1.
Click File > Open.
2.
Select the previously saved automesh_ready.hf file and click Open.
3.
4.
Select the edge deviation subpanel and set the following options:
min elem size = 0.5
max elem size = 15.0
max deviation = 0.1 (Defines the maximum allowable distance between an edge of the surface
being meshed and an element edge)
max angle = 15.0 (Defines the maximum allowable angle between two element edges).
mesh type = mixed
first order toggle is set
5.
Click surfs >> displayed from the pop-up window.
6.
Click mesh.
7.
Click return twice to accept the mesh.
8.
Graphically review the mesh. Notice large element size occurs at planar surfaces and smaller element
size is applied to capture curved surfaces.
9.
Click File > Save As... and enter the file name as automesh_edge_deviation.hf.
10. Click Save.
Step 7: AutoMesh surface deviation

Similarly to the edge deviation subpanel, meshing behavior on this subpanel is driven by distances
between flat elements and model geometry. When HyperMesh uses flat elements to approximate a curved
surface, there is always a discrepancy between each element and the actual curve of the surface, because
the element uses a straight line between two nodes.
The surface deviation automesh method chooses the mesh density based on the severity of this deviation.
Where the threshold deviation would be exceeded, HyperMesh uses a larger number of smaller elements to
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reduce the deviation.

For more information, please refer to the online help.
Step 8: AutoMesh rigid body mesh (R-mesh)

Rigid bodies are surfaces that are expected to impact other model surfaces, but are rigid enough that they
themselves are not expected to deform as a result of the impact. When modeling the results of a stamp
pressing down on a metal sheet, its important to model the shape of the stamp because that determines the
shape of the metal sheet after being pressed. However, it is not important to model the stresses placed upon
the stamp tool. Therefore, the mesh quality of rigid tooling is less important in the comparison of the captured
shape of the tools.
The R-Mesh macro directly accesses the AutoMesh/rigid body mesh feature. You can find the R-Mesh
macro under both the Radioss One Step and Incremental_Radioss user profiles.
1.
From the File menu, click Open.
2.
Select the automesh_ready.hf file and click Open.
3.
From the Mesh menu, select R-Mesh.
4.
Modify Maximum edge length = 15.0

Note:
The fillet angle field is used to specify a maximum angle across which elements can be
maintained. If at any time two adjacent elements normals would exceed this angle, HyperForm
creates a new set of nodes between them to maintain clean feature lines. Using a higher value
would result in nodes spanning along the feature line.
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5.
Click Mesh
6.
Click surfs >> displayed from the pop-up window.
7.
Click proceed.
8.
Click Close to close the panel.
9.
From the File menu, select Save As... and enter the file name as automesh_R_mesh.hf.
10. Click Save.
Step 9: AutoMesh Re-mesh an existing local mesh

AutoMesh enables you to re-mesh elements. In HyperForm, you can remesh elements when no geometry
exists.
The remeshing function is activated when you switch the entity selector from surfs to elems. Elements are
remeshed with the use of the HyperMesh inferred surface algorithm, if geometry for the selected elements
needs to exist in the model. The inferred surface algorithm interpolates geometry data from the selected
elements in order to create new mesh.
When elements are selected to be remeshed, there is the break connectivity option and the vertex angle
parameter. The break connectivity option detaches the node connectivity between adjacent selected and
unselected elements. This allows you to adjust the node densities along the boundary of the selected
elements. The vertex angle parameter defines the placement of vertices along the boundary of the selected
elements. If the angle between two adjacent element edges along the boundary is less than the specified
angle, a vertex is placed at the meeting point of the two edges. Anchor nodes create the effect of a fixed
point on the inferred surface (which is derived from the existing mesh) and keep the location of the anchor
nodes intact.
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1.
Click File > Open.
2.
Select the Bpillar_AutoMesh_remesh.hf file and click Open.
3.
4.
Change the entity selector from surfs to elems.
5.
Click elems and select by sets from the pop-up menu.
6.
Check refine and click select. Notice that a set of elements are highlighted.
7.
Input element size = 1.0 and make sure break connectivity is selected.
Also verify that all the settings are as shown in the image below:
8.
Click mesh to refine a local region and click return. Review the result as shown in the image below.
You are still in the mesh panel.
In the next few procedures, you will rebuild the meshs transitional region by re-meshing elements with
applied anchor nodes.
9.
Click elems and graphically select elements as shown in remesh region in the image below.
10. Click nodes and graphically select nodes as shown in anchor nodes in the image below.
11. Toggle break connectivity back to keep connectivity.
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12. Click mesh and click return. Notice the mesh transition is re-built as shown in the image below.
Step 10: Equivalencing nodes

To ensure connectivity between the elements, you need to equivalence any coincident nodes in the model.
The equivalence operation identifies any location where two or more nodes exist within the specified search
tolerance. During equivalence, one of the nodes is retained, and any element definitions referencing the other
nodes are re-defined to use the retained node.
1.
Click Mesh > Check > Components > Edges.
2.
Click comps and select component by clicking any element on screen.
3.
Click select.
4.
Input tolerance = 0.2. (This specifies the minimum coordinate distance between two nodes.)
5.
Click the preview equiv button.

This identifies duplicated nodes and highlights them with a circle. The nodes that preview equiv
displays can be equivalenced.
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6.
Click equivalence to merge coincident nodes.
7.

You have fixed the connectivity problem of one side of the refined region. The remaining connectivity
problems can be fixed using the same technique. For the purposes of this tutorial, you will load the final
result for reviewing directly.
8.
9.
Select the Bpillar_AutoMesh_remesh_final.hf file and click Open.
10. Review the final result.
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It is always a good practice to check the quality of the mesh before running the analysis. HyperForm allows
you to check different quality criteria such as conformance to the surface topology, Jacobian, warpage,
length, skew angle, etc. Conformance to surface topology is a visual check that ensures that the mesh lies
on the surface and none of the elements are warped. Checks should be done to ensure that features are
being reasonably captured (fill plot check). Mesh connectivity is equally as important. This can be checked
using the edge check macro.
In general, the below element quality will be satisfied to acquire better analysis result accuracy:
Maintain connectivity
Remove duplicate elements
Avoid zero-length elements (recommended value larger than 0.1)
Warpage is recommended to be less than 30
Larger Jacobian values are better. No negative Jacobian value is allowed. It is recommended to have
a Jacobian value larger than 0.1.
Tools
The tutorial uses the Element Quality Report module and the following menu options:
Mesh > Check pull-down menu:
o
Elements > Check Elements
Elements > Quality Index
Components > Edges
Mesh > Edit pull-down menu:

o
Elements > Combine Elements
Elements > Split Elements
Exercise: Mesh quality checking and improving

This exercise uses the model file mesh_quality.hf.
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1.
2.
Browse to the file <installation_directory>\tutorials\mfs\hf\1Step\mesh_quality.

hf.
3.
Click Open.
Step 2: Review the 2D mesh quality report

1.
From the Utility Menu, under Model, click on Check Elems.
2.
Click Quality Report.

Notice a 2D Element Quality Report dialog appears. The Quality Report Tool will check all the 2D
elements regardless of whether they are displayed on or off.
3.
Modify the following values:

Warpage > 30.0
Length < 0.1
Jacobian < 0.1
4.
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Warpage > 30.0 => # of failed Elems = ______________
5.
Length <0.1
=> # of failed Elems = ______________
Jacobian < 0.1
=> # of failed Elems = ______________
Click Close to close the dialog.
Step 3: Check connectivity

1.
Click Mesh > Check > Components > Edges.
2.
Ensure the comps button is highlighted and graphically pick any element to select the component.
3.
Set the tolerance = 0.01 and toggle to find: free edges.
4.
Click find edges.

HyperForm generates a new êdges component. Notice red 1D edge elements are generated along the
free boundary.
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5.
Using the Model Browser, expand the Component folder and uncheck all geometry except the
êdges component.
You should see only the red lines for the free mesh boundary. In the next step, you will find elements
attached to the êdges elements to visually verify this.
6.
7.
Click Shift + F5 to open the Find Attached Entities panel. Select the find attached subpanel.
8.
Click the yellow elems button and select displayed.
9.
Click find. Repeat steps 8 and 9 again to find 2 layers of elements attached to the edge elements.
Note:
Two layers of elements attached to êdges elements are displayed back on screen. You can
click Find Attached more times to find more layers of elements. Any missing holes or elements
can be indication of connectivity problems. This method can be used to localize the
disconnecting areas.
10. In the Model Browser, right-click on the Component folder and select Hide to turn off the display of all
components.
11. Right-click again and select Show to display all components back on screen.
12. Click return to go back to the main menu.
13. In the Model Browser, right-click on the êdges component and select Delete.
14. Click Yes to confirm the action.
Step 5: Visually review the mesh quality

1.
From the toolbar, click the Shaded Elements and Mesh Lines
icon and select Feature Line mode
.
2.
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From the toolbar, left-click the Dynamic Rotate
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region and randomly rotate the model for reviewing. Notice two shaded areas as indicated in the image
below. Those areas are indications of elements with poor quality. (You can also use the User Views
icon and retrieve the saved views view1 and view2 view to review them.)
Shaded areas
3.
From the toolbar, click the Shaded Elements and Feature Lines
Elements and Mesh Lines
4.
icon and switch to Shaded
Visually review the two areas again with the mesh line displayed. Notice the mesh quality problem.
Step 6: Manually split an element using the split panel

In this step, you will use the split subpanel to manually fix an element quality problem. Four methods used
to split elements free-form are illustrated below.
HyperForm prompts you to build a line to split these elements using one of the four methods. Draw a window
as shown in the figure below.
Types of element splits
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1.
From the toolbar, click the user view
2.
Click the F6 key to access the combine elements panel.
3.
Select the split subpanel and change the selector from displayed elems to elems.
4.
With elems activated, graphically select the element as indicated in the image below.
5.
Under Splitting line:, click points to draw a line passing through two nodes (two black circles in the
image) of the selected element. Refer to the image below.
6.
Click split to split the element.
icon and click restore1 to retrieve a saved view.
Step 7: Use the Check Elements panel

1.
Click F10 to open the Check Elements panel.
2.
With 2-d selected, click duplicates to check if there are any duplicated elements.
Notice that the message bar displays "0 duplicate elements were found". If any duplicate element is
identified, it will be highlighted.
3.
Click length.
Notice the minimum length is larger than 0.0 from the message bar. Any element with length equal to or
less than 0.0 must be fixed.
4.
Click jacobian.
Notice the minimum length is larger than 0.0 from the message bar. Any element with Jacobian value
equal to or less than 0.0 must be fixed.
5.
In the warpage field, enter 30.0.
6.
Click the warpage button. Notice that the message bar displays "25 of 4668 (1%) failed. The maximum
warpage is 176.01."
7.
Click the save failed button to store the failed elements (warpage > 30.0) into a user mark.
Notice message bar displays "The highlighted elements have been placed in the user mark".
8.
Click return twice to close the panels.
9.
In the Model Browser, right-click on the Component folder and select Hide.
10. Press Shift+F5 on the keyboard to open the Find panel.
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11. Open the find entities subpanel. Click elems and select retrieve to retrieve elements from the user
mark.
Notice the message bar displays "25 elements added by retrieve. Total selected 25".
12. Click find to display the 25 elements on the screen.
Elements with warpage >30.0 are displayed on the screen.
13. Press the F key to fit the model to the screen.
Step 8: Display all elements

1.
Click Shift+ F6 key to open the Edit Elements panel.
2.
In the plate elements subpanel, click the selector to change from split all sides to divide quads.
3.
Click elems and select displayed.
4.
Click split. The displayed quad elements are divided into trias elements.
5.
In the Model Browser, right-click on the Component folder and select Show.
Step 9: Use the Quality Index

1.
Click Mesh > Check > Elements > Quality Index.
2.
Under pg1 (page 1), uncheck max size, aspect ratio and skew.
3.
Under threshold, input min size = 0.1 and warpage = 30.0.
4.
Click
5.
Uncheck all features EXCEPT # of trias.
right next to pg1 and change to pg2.
Notice elements with color on screen indicate they fail to satisfy the activated quality check.
Quality Index function allows element's quality to be improved by node optimize method and element
optimize method.
-
For node optimize method, click node optimize and select a node on the screen. HyperForm
repositions the node on the inferred surface to obtain the best possible quality for all elements
attached to that node.
For element optimize method, click element optimize and select an element on the screen. The
locations of all its nodes move on the inferred surface to obtain the best possible quality for that
element and its neighbors.
In this, you will leave Jacobian = 0.3 .

6.
From the tool bar, click the user view
7.
Click node optimize and graphically pick the node as indicated in the image below.
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Notice the selected node is relocated and element quality is improved. The associated element is also
changed to transparent mode.
8.
Click return.
Step 10: Compare 2D mesh quality improvement

1.
Click Applications > Radioss One Step.
2.
From the Utility Menu, under Model, click on Check Elems.
3.
Click the Quality Report macro.
4.
Modify the following

Warpage > 30.0
Length < 0.1
Jacobian < 0.1
5.
Click Check.
6.
Compare the values to the ones written in step 3.
7.
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Undercut is a term used in part design that refers to situations that lead to die lock condition when the part
is being formed. In real-time forming applications, parts are designed in such a way that they get locked if
formed. Split dies and punches with negative rake angles are used to form such parts to avoid this situation.
But for the simulation purpose in One-Step analysis, the part is tilted in such a way that the Z-axis of the part
matches with the Z-axis of the punch and the die. This process of aligning the part axis with the tool axis is
called Autotipping. The angle to be tilted is calculated automatically by HyperForm.
Stamping can also be done in any of the three principal axes or an arbitrary axis in space by using
the stamping direction subpanel in the Autotip panel.
The autotipping option will reduce the draw depth by making the z-axis as the stamping direction.
In this tutorial you will learn to check for undercut and remove it in a part by using the Autotip feature.
This tutorial assumes that you are familiar with functionalities such as creating components, geometry
cleanup, and meshing. Information on these topics can be found in the online help.
Tools
The tools used in this tutorial can be found in the Radioss One Step user profile.
Autotipping
Allows you to set the user defined stamping direction for the part. It can also help you to tip (orient) the
part in the formable position along the user defined stamping direction.
Undercut check panel

Allows you to identify all the elements in the displayed part that may lead to a die-lock condition. The
stamping direction is assumed to be along the global z-axis.
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Exercise: Undercut checking and Autotipping

This exercise uses the model file mesh_quality.hf.

1.
2.
Browse to the file <installation_directory>\tutorials\mfs\hf\1Step\mesh_quality.

hf.
3.
Click Open.
Step 2: Check the undercut in the part

1.
Click Tools > Undercut Check.
2.
Click comps and select the mesh component.
3.
Click check undercut.

Notice that the header bar displays the number of elements with an undercut problem. Any element
detected with an undercut problem is highlighted on screen. You can click the saved failed button and
save the undercut elements into a user mark to be retrieved and fixed later.
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In One-Step analysis, minor undercut problems occurring at non-critical areas are unavoidable and
acceptable. When significant undercut is detected, Local bending/Unbending in the Advanced panel
is automatically disabled for better result accuracy.
In this exercise, the undercut problem is not severe and therefore you will leave the model as it is.
4.
Click return.
Step 3: Autotip the model

1.
Click Tools > Autotipping.
2.
Select the autotip subpanel.
3.
Verify the entity selector is set to comps and select the mesh component.
4.
5.
Click calc autotip.

Notice the angle to be tilted is displayed on the header bar.
6.
Click autotip.
This action will tilt the part by an angle calculated by HyperForm to avoid the die lock situation during
forming. The default tipping direction would be +Z. Click F to fit the model to the screen if the display is
not desirable.
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Step 4: Autotip the model along a user defined plane

1.
Click the stamping direction radio button.
2.
Click on the vector selector and select the N1 N2 N3 option.
3.
Click on any 3 nodes as shown below along the tail of the part and click on set.
4.
Open the autotip subpanel.
5.
Verify the entity selector is set to comps and select the mesh component.
6.
7.
Click calc autotip.

Notice the angle of orientation is displayed on the header bar.
8.
Click autotip.
Note: Similarly the tool tipping can performed as per the user specific requirements.
N1 N2 N3 node selections
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HF-1000: One-Step Stamping Simulation

In this tutorial, you will learn how to:
Import geometry data
Clean up the geometry
Create a finite element mesh
In preparation for running the model, you will specify blankholders and set constraints. After running the
analysis, you can view the results in contour plot, blank shape, and FLD contour modes.
Tools
This tutorial uses the following panels available in the Radioss One Step user profile:
Remove Holes panel
Mesh panel
Component panel
Constraints panel
Blankholder panel
Blank Shape panel
Formability panel
Exercise: Basic Draw Forming Analysis

This exercise uses the model file part1a.igs.
The model comes in clean after importing. There are no free edges for this model. All of the edges are
stitched. However, there are many small surfaces in the part. You will minimize the number of surfaces in the
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following steps.
Step 1: Import the model file

1.
From the File menu, select Import....
2.
3.
Click the Select Files icon

<installation_directory>\tutorials\mfs\hf\1Step\part1a.igs.
4.
Click Import and then click Close.
Step 2: Save a HyperForm data file

1.
From the File menu, click Save As....
2.
Enter the file name and extension as part1a.hf.
3.
Click Save.
This saves the file as a database file, in the current working directory. The Save asoption can be used
to save the file at the desired location.
Step 3: Change the component color

1.
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In the Model Browser, expand the Components folder.

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2.
For the components lvl1 and lvl7, click on the colored box to select a color of your choice.
Notice the color of the components has changed.
Step 4: Suppress lines

1.
Click Geometry > Edit > Surface Edges > (Un)Suppress.
2.
Click lines and select all from the pop-up menu.
3.
Click suppress.
This suppresses all of the internal edges that are shared by the surfaces and converts the model into one
big surface.
Stay in the same panel for the next step.
Model after lines have been suppressed
Step 5: Add fillet features

1.
Click lines again, and select the suppressed lines as shown in the image below.
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2.
Click unsuppress.
The selected blue lines become green lines to define the corner of the fillets. (Green lines can be noticed
when toggled to By Topo.) Later when you are meshing, node seeding can be generated along the green
lines for better mesh quality control.
3.
Click return.
Edges to be unsuppressed prior to meshing
Step 6: Remove a hole from the surface

1.
Click Geometry > Defeature. Make sure the pinholes subpanel is selected.
2.
With the yellow surfs button active, choose the flat surface.
3.
Click the pinholes button and select all.
4.
Type 40 in the diameter field.
5.
Click find.
6.
Notice the xP display on screen indicating a pin hole has been identified with a diameter less than 40.
7.
Click delete.
8.
Click return.
Step 7: Create a finite element mesh

1.
2.
Click surfs.
3.
Select displayed.
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4.
Use the settings below :

Toggle is set to interactive
Element size = 7
Mesh type = mixed
Toggle is set to elems to current comp
Toggle is set to first order
Switch is set to break connectivity
Size and skew are selected
5.
Click mesh.
6.
Click return twice to close the panel.
Step 8: Load the material library

1.
Click Setup > Materials and select the library subpanel.

Notice default material types are provided under Materials in file.
2.
Verify that CRDQ steel is loaded under Materials in memory. If not, click >> and load CRDQ steel
under Materials in memory.
3.
Click return.
Note:
The default material for one-step solver is located at [HyperWorks installation] /hm/
scripts/hyperform/hf.mat. You can edit this file and store user-defined material data into
this library.
Step 9: Create and update the elements to the component

1.
Click Setup > Components.
2.
Click Component: and enter Part.
3.
Click Material: and select CRDQ Steel.
4.
If you created an FLD curve, click FLD curve and select the curve. Otherwise, leave it blank, and
HyperForm will automatically create an FLD curve.
5.
Click thickness= and enter 1.
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6.
Select a color.
7.
Click create to create the component.
8.
Click elems and select all elements to be defined in the part component.
9.
Click move.
10. Click update.

11. Click return.
Step 10: Set constraints

1.
Switch to shaded mode by clicking on this button from the header bar:
2.
Click Setup > Constraints.
3.
Click nodes and select on plane.
4.
Set the direction selector to x axis.
5.
Click B.
6.
Pick a point on the symmetric plane as shown in the image below.
7.
8.
Below Constraint Type, click X.
9.
Click size= and enter 10.
10. Click update.

11. Click return.
Constraints along the symmetric edge
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Step 11: Specify a blankholder

Blankholders can be defined as the upper and lower holding surfaces that control metal flow around a shape
to be formed in a draw operation. They supply a restraining force on the material during the pressing
process.
HyperForm allows you to define the blankholder force in two ways: on element and on edge. The correlation
between the magnitude and level of the applied forces is always available. Edge blankholder force application
allows you to restrain an edge by enabling automatic selection of all nodes between two user-defined nodes
along a free edge of a part.
You can define the blankholder force in two ways: tonnage force or pressure level (high, medium and low).
Note
The pressure level is proportional to the area of blank under the blankholder as well as thickness. A
pressure level of 2MPa, 5MPa and 10MPa for a 1mm blank has been chosen as a reference for
Low, Medium, and High (based on practical experience). The tonnage (metric ton unit) is equivalent
to the pressure times the blankholder area normalized/scaled by the thickness (1 metric ton =
9810N).
1.
Click Setup > Blankholder.
2.
Click blankholder and type Blankholder 1.
3.
Set the pressure level to low.
4.
Click friction = and enter .125.
5.
6.
Toggle the switch to z-axis and pick a node on the binder (flat region) for B (base node).
7.
Click tolerance = and enter .3.
8.
Select elements on the binder region
9.
Click color and select a color of your choice.
10. Click create.
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You can see the corresponding tonnage force in the tonnage= field.
11. Click return.
Step 12: Save the file

1.
Click File > Save As....
2.
Enter the file name as part1a_complete.hf.
3.
Click Save.
This saves the file in the current working directory. The Save asoption can be used to save the file at
the desired location.
Step 13: Run the analysis

1.
Click Setup > Run Analysis.
2.
Click project: and select the saved file part1a_complete.
3.
Click run analysis.
4.
Click view output.
5.
Click 1- to review information about the analysis.
6.
Click view output again.

ASCII result output information is displayed.
Notice estimated press tonnage = 0.391E+02 (tons)
7.
Click close to close the summary.
Step 14: View the results

1.
Click load results while in the same panel.
2.
Click return to exit the Run Analysis panel.
3.
Press D on the keyboard and click the toggle switch to loadcols. Click on None to turn off the display of
constraints.
4.
In the Model Browser, expand Components and click on the Geometry icon
to turn off the geometry display.
5.
Click Tools > %Thinning.
6.
When you are finished viewing results, click return.
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for each component
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Contour plot show ing % thinning
Step 15: View the blank shape profile

1.
Click Tools > Blank Shape.
2.
Select Initial to display the minimal blank shape.
3.
Select Final to view the original part geometry.
4.
Click return.
Step 16: View the forming limit diagram

1.
From the Utility Menu, under Results, click Formability.
2.
Click component and select the blank component.
3.
Click Create FLD.
4.
Pick a point on the curve (which represents a corresponding element on the model) or pick an element
on the model. The corresponding major (y) and minor (x) strain are displayed in the header bar.
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Forming Limit Diagram of part1a
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In this chapter, you will learn how to increase blankholder pressure and compare the results from different
pressure levels. The result from the previous tutorial, One-Step Stamping Simulation (HF-1000), will be used
to compare the result from this tutorial.
Tools
This tutorial uses the following panels, which are available in the Radioss One Step user profile:
Blankholder panel
Blank Shape panel
Formability panel
Exercise: Increasing Blankholder Pressures

This exercise uses the model file Blank_holder.hf.

1.
2.
Browse to the file <installation_directory>\tutorials\mfs\hf\1Step\blank_holder.

hf.
3.
Click Open.
Step 2: Edit the blankholder and save as a different file name

1.
Click Setup > Blankholder.

The blankholder parameters are already set up from the previous run.
2.
Click blankholder and select Blankholder 1.
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3.
Set the pressure level to High.

Notice value in tonnage = is changed from 21.127 to 105.634.
4.
Click update.
5.
Click return.
6.
From the File menu, click Save As..
7.
Enter the file name as blank_holder_complete.hf.
8.
Click Save.

1.
2.
Verify project = is set to blank_holder_complete.
3.
Click run analysis.
4.
Click load results when your job has finished.
5.
Click return.
Step 4: View the forming limit diagram

1.
Click Tools > Formability.
2.
Click comps and select part.
3.
Click create FLD.
Note:
4.
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Pick a point on the curve (which represents a corresponding element on the model) or pick an
element on the model. The corresponding major (y) and minor (x) strain are displayed in the
header bar. The corresponding element ID is also displayed in the Formability panel.
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Step 5: View the thinning

1.
Click Tools > Thinning.
2.
Click Contour.
3.
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HF-1020: Applying Drawbeads and Performing Circle Grid Analysis

In general, the material flow is controlled by the blankholder and a resultant restraining force is created by
friction between the tools and the blank. However, during a forming process, it is common that a blankholder
does not make contact with an entire blank. Therefore, material flow is usually not fully controlled by the
blankholder.
When a high restraining force is required, a higher blankholder force must be applied, which could cause
wear in the tools. A local control mechanism is therefore necessary to restrain the material flow sufficiently at
relatively low blankholder pressure. This is achieved by applying drawbeads.
The drawbead creates a restraining force by cyclically bending and unbending the sheet as it traverses the
drawbead, causing strain hardening and a change in the strain distribution with consequential thinning of the
blank.
HyperForm allows you to define a restraining force for the drawbead in two ways: qualitative (pressure level)
or quantitative (restrain force). You can also define a lockbead, which will apply a 100% restraining condition.
HyperForm provides drawbead function both for One-Step and Incremental analysis. The interface of the
Drawbead panel is switched automatically based on the currently-selected analysis type.
In this tutorial, you will learn to define drawbeads for One-Step analysis. You will also use the Circle Grid
panel to show relative magnitudes and associated direction of major and minor strains
Exercise 1: Applying Drawbeads to a Model
Exercise 2: Performing Circle Grids Analysis
This tutorial uses the Drawbeads panel, Run Analysis macro, and the Circle Grid panel.
Exercise 1: Applying Drawbeads to a Model

This exercise uses the model file drawbead_1step.hf.

1.
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2.
Browse to the file

<installation_directory>\tutorials\mfs\hf\1Step\drawbead_1step.hf
3.
Click Open.
Step 2: Add a drawbead to the existing model

1.
Click Setup > Drawbeads.
2.
Select the restrain subpanel.
3.
Click drawbead and type Drawbead1.
4.
Pick a drawbead condition. Force level = medium.

(High is 80%, Medium is 50% and Low is 20% of necking condition).
5.
Select the green color.
6.
With the halo surrounding node list, pick two nodes on the blank as indicated in the image below to
define the drawbeads.
7.
Click create.
Notice a message shows "The drawbead set has been created". A line is created representing
drawbeads.
Step 3: Update drawbeads using the calculate subpanel

Modeling the exact drawbead geometry requires a large number of elements, which increases CPU time
dramatically. A practical approach is to use an equivalent drawbead model by representing the drawbead
analytically and providing a constant drawbead restraining force and closure force.
Use the calculate subpanel to determine the closure and restraining force based on drawbead dimensions.
The restraining force is the value of the force (per unit length) applied by the bead in the plane of the blank
surface. The closure force is the force (per unit length) required in the perpendicular direction to keep the
drawbead closed.
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1.
Select the green calculate button.
2.
Click material: and select the current blank material (CRDQ steel).
3.
Verify that the drawbead height, shoulder radius, and drawbead radius are set to 6.25.
4.
Click calculate. Notice output restraint force, closure force and necking result are calculated
accordingly.
5.
Click update to go back to the Drawbeads panel.

If the geometry is such that a necking condition exists, the message, Material Locking Condition is
displayed on the status bar.
6.
Click update.
7.
Click return.
Step 4: Save and run the analysis

1.
2.
Enter the file name as drawbead_1step_complete.hf.and click Save.
3.
4.
Make sure project: is set to drawbead_1step_complete.hf.
5.
Click run analysis.
6.
Click load results when your job has finished.
7.
Click return.
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Step 5: View the thinning contour plot

1.
Click Tools > % Thinning to view the thinning contour plot.
2.
Click contour to review the result.
3.
Step 6: Review the Forming Limit Diagram

1.
Click Tools > Formability.
2.
Click comps and select the part component.
3.
Click Create FLD.
4.
Click return.
Exercise 2: Performing Circle Grids Analysis

This exercise uses the result from Exercise 1, drawbead_1step_complete.hf.
In circle grid analysis, a sheet of metal is prepared by etching a circle grid onto the surface. Plastic
deformation in the steel during the forming operation causes the circles to deform into ellipses. The plastic
strain at each circle is then calculated from the major and minor diameters of the ellipses.
In HyperForm, the Circle Grid panel allows you to show relative magnitudes and associated direction of
major and minor strains with respect to deformed mode by displaying circles drawn on the blank surface. A
result file needs to be loaded before performing circle grid analysis.
Step 1: Review circle grids

1.
Click Tools > Circle Grid.
2.
Pick the elements you want to display.
3.
Select Initial Circle to show the initial status of the blank.
4.
Select Deformed Circle to show the final deformed status of the blank.
5.
Set the switch to cir & dir, cir only, or dir only to show the circles and/or major and minor deformed
direction.
6.
Click draw.
The circle grid is displayed. If you change the display method, click draw again to refresh the screen.
7.
To clear the circles and/or directions, click clear.
8.
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Circle grids on initial and deformed blanks
Step 2: Press tonnage output

The HyperForm solver also outputs the estimated press tonnage required to form the part. The press tonnage
is written out in the output file.
1.
2.
Click view output.
3.
Select 1- to view the text in graphics area. Scroll down toward the bottom. The estimated press tonnage
output can be seen as shown in the figure below.
4.
When finished, click Close to close the report, and click return to close the panel.
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Return to Part Feasibility Tutorials
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HyperForm One-Step analysis can generate a LS-DYNA input file (a dynain file) containing forming results.
This effectively allows users to initialize a crash model with forming effects. The preferred quantities to be
used for forming initialization are thickness and plastic strains (the stresses are set to zero).
This tutorial features the procedures for preparing an input file for a crash simulation, and illustrates how to:
Perform autotipping on the model
Perform undercut checking
Create a dynain file using the HyperForm One-Step solver
Position the stamped part into a car coordinate position
Export the stamped part for use in a crash simulation
This tutorial uses the following panels:
Autotipping panel
Undercut Check panel
Advanced panel (Dyna/Nastran output option)
Position tool (Mesh menu)
Exercise: Transferring Forming Results to Crash Analysis

This exercise uses the model file bumper_car_coordinates.hf.
Step 1: Load the model file and change the model orientation
1.
2.
Browse to the file

<installation_directory>\tutorials\mfs\hf\1Step\bumper_car_coordinates.hf
file.
3.
Click Open.
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The structure part (bumper_car_coordinates.hf) is not oriented with respect to the stamping
direction (z-axis). Prior to running the forming simulation and transferring the forming to the part in a
crash simulation, it must be re-oriented with respect to the z-axis. Refer to the image below.
Step 2: Autotip the model

1.
Click Tools > Autotipping.
2.
Select the autotip subpanel.
3.
Click comps and select the bump_car_co-ord component.
4.
Click select.
5.
Verify that the toggle is set to full model.
6.
Click calc autotip.

Notice that the message bar displays the potential rotation angles for autotipping with respect to the
stamping direction (z-axis)
7.
Click autotip.
8.
Click the F key on the keyboard to fit the model to the screen.
9.
Step 3: Perform undercut checking

1.
Click Tools > Undercut Check.
2.
Click comps and select the bump_car_co_ord component.
3.
Click the green check undercut button. Notice no elements get highlighted on the screen. The model
passes the undercut check and no problems are detected.
Note: A set is created when perform undercut checking. You will delete the set before solving the
problem in One-Step analysis.
4.
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5.
In the Model Browser, expand the Set folder and right-click on the hf_undercut_set set.
6.
Click Delete and select Yes to confirm the action.
Step 4: Request LS-DYNA/Nastran output format

1.
In this step, you will request output format in LS-DYNA and Nastran solver formats for forming analysis.
This allows HyperForm to write out a results file that can be directly used to initialize a structural
analysis model. The names for the output files are:
[filename]_thk.nas and [filename]_dyna.k corresponding to Nastran and LS-DYNA
solvers, respectively.
[filename]_thk.nas contains the mesh data along with the nodal thickness.
[filename]_dyna.k contains the mesh and the nodal thickness, followed by the stress tensor
and plastic strain at each integration point within an element.
2.
Click Setup > Advanced.
3.
Click Radioss/Dyna/Nastran output. This option will take you to another panel.
4.
Toggle the option to w/o stress (zero stress will be written to the dynain file).
5.
Click comps.
6.
Click comps again and check the bump_car_co-ord component.
7.
Click select.
8.
Click return twice to close the panels.

1.
2.
Enter the file name as bumper_car_coordinates_complete.hf and click Save.

1.
2.
Click project: and select bumper_car_co_ordinates_complete.
3.
Click run analysis.
4.
Click return when the analysis is finished.

Note:
Notice several files are generated when 1 step analysis is finished:
bumper_car_co_ordinates_complete.parm : HFSolver Input deck generated by HyperForm.

bumper_car_co_ordinates_complete_dyna.k : Contains the mesh and the nodal thickness,
followed by the stress tensor and plastic strain at each integration point within an element.
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bumper_car_co_ordinates_complete_thk.nas : Contains the mesh data along with the nodal

thickness.
bumper_car_co_ordinates_complete.out : ASCII output file contains model and run information.
This file can be used to debug model and system level problems.
bumper_car_co_ordinates_complete_opt.dat : Input deck for optimization runs with
HyperStudy
bumper_car_co_ordinates_complete.dat : Input data summary.
Step 7: Delete the current session and load the resultant DYNAIN file with the
forming result
1.
Press F2 to open the Delete panel.
2.
Click delete model.
3.
Click yes to confirm deletion of model.
4.
Click Applications > Incremental LsDyna to change the user profile.
5.
From the File menu, click Import.
6.
Click the Import Solver Deck icon
7.
Click the folder icon

and browse to the location where the previous analysis was run to select the
file bumper_car_co_ordinates_complete_dyna.k.
8.
Click Open to select the file.
9.
Click Import to import the file and Close to close the dialog.
The output file bumper_car_co_ordinates_complete_dyna.k has the identical format as the LSDYNA DYNAIN file. During the import of the *_dyna.k (dynain) file, only the node and element
definitions are read into HyperForm. The initial stress and plastic strain quantities are automatically
placed into a new file with an .hmx extension (i.e. filename_dyna.k.hmx) and HyperForm
automatically activates an INCLUDE control card to retain the information. More detail regarding DYNAIN
file will be discussed in HyperForm incremental analysis.
Notice the warning message "No renumbering or rotation is allowed. Stress and strain history will get
written to a .hmx file. Continue?"
10. Click Yes.
If the *_dyna.k (dynain) file contains stress quantities, no rotations of the component are allowed. The
stress tensors are written with respect to a global coordinate system, and would require a suitable
transformation. In this exercise, because the file contains zero stress, rotations of the component are
allowed.
Step 8: Position a stamped part back to car coordinate position
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In this step, you need to orient the model *_dyna.k file (dynain file) which has the information from the
One-Step forming run, back to the car co-ordinate system model for crash analysis. You will first import the
original bumper_car_coordinates.hf and re-position forming result in z-axis (*_dyna.k (dynain) file )
back to the original vehicle coordinate.
1.
From the File menu, click Import.
2.
Select the Import HM Model icon
3.
Click the folder icon
4.
Select the bumper_car_coordinates.hf file.
5.
Click Import.
6.
Click the F key on the keyboard to fit the model to the screen.
7.
Click Mesh > Position > Components.
8.
Click the selector and choose comps.
9.
Click comps.
. In the file browser dialog, switch the Files of Type field to All Files.
10. Check the 1 component (import from *_dyna.k file) and click select.
11. Click from: N1, N2, and N3 and select three nodes on the part in forming coordinates (part in gray color)
as shown below.
12. Click To: N1, N2, and N3 and select three nodes on the part in car coordinates (part in blue color) as
shown below.
Note:
The locations and selection sequence of N1, N2 and N3 nodes in "from" will need to exactly
match the corresponding N1, N2 and N3 nodes in "To". This ensures the transformation
(consisting of translations and rotations) that maps the differences between the two sets of
nodes is applied to the selected entities until they are relocated.
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13. Click position to reorient the stamped part back to car coordinate position.
Notice two models are overlapped with each other.
14. Click F2 and jump to the Delete panel.
15. Change the selector to comps.
16. Click comps again and select the bump_car_co-ord component.
17. Click select.
18. Click delete entity. The original part in vehicle is deleted.
19. Click return twice to go back to the main menu.
Step 9: Export the model as a new LS-DYNA input file

1.
From the File menu, select Export....
2.
Verify the template field is set to LsDyna.key (LsDyna template).
3.
Click File: and type the name bumper_crash_input.key.
4.
Click Export and click Close.
Step 10: Review the LS-DYNA input file and the *.hmx file
1.
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Open any text editor and load the bumper_crash_input.key file for reviewing.

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Notice:
A. The dyna input file contains the thickness distribution from the One-Step analysis.
*ELEMENT_SHELL_THICKNESS
$
EID
PID
N1
N2
N3
N4
13
12
21
23
14
1.00013
14
1.00026
21
1.00026
15
22
1.0004
24
1.00045
14
1.00036
23
1.0004
1.00036
23
1.00038
25
1.0004
16
1.00073
1.00097
B. Plastic strains are carried and included in the *_dyna.k.hmx file

*INCLUDE
[ full path ] / bumper_car_coordinates_complete_dyna.k.hmx
C. bumper_car_coordinates_complete_dyna.k.hmx contains residual strain data from the

1Step forming analysis.
*INITIAL_STRESS_SHELL
*INITIAL_STRESS_SHELL
$ EID NPLANE NTHICK
$ T SIGXX SIGYY SIGZZ SIGXY SIGYZ SIGZX EPS
Where "EPS" is Effective Plastic Strain
D. Forming related control cards need to be deleted/modified accordingly before running the crash
analysis
*CONTROL_SHELL
*CONTROL_HOURGLASS
*CONTROL_BULK_VISCOSITY
*CONTROL_CONTACT
*CONTROL_PARALLEL
*CONTROL_ENERGY
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*CONTROL_ACCURACY
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HF-1040: Laser Weld

A laser-welded blank consists of different thicknesses of metal that has been laser-welded together into a
sheet. In addition to achieving direct cost reductions through the more efficient use of materials, tailored
blanks also offer manufacturers the potential for greater flexibility in design. Manufacturers currently apply
several types of joining processes to weld coated-steel tailored blanks such as seam welding, high-frequency
welding, electron beam welding, and laser welding.
In this tutorial you will learn to simulate the welding of two blanks with different thickness and material
properties.
To set up the analysis for a laser weld, you need to define two (or more) components in the supplied model.
The components may be assigned to different materials and may have different thickness and FLC curves.
You use a default FLC curve for one component and create a user-defined FLC curve for another component.
In the next step, you will create a sample FLC curve using minor and major strain data.
Tools
FLD Curves panel
Component panel
Save panel
Run panel
Exercise: Laser Welded Blank

This exercise uses the model file laser_weld.hf and Laser_weld_FLC_curve.csv

1.
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2.
Browse to the file <installation_directory>\tutorials\mfs\hf\1Step\laser_weld.hf
3.
Click Open.
Step 2: Load the FLD curve

1.
From the Setup menu, click FLD Curves.
2.
Click the library subpanel.
3.
Click file = and select Laser_weld_FLC_curve.csv.

The figure below shows the FLD curve panel.
On the left-hand side of the panel, under Curves in file, the name of the curve (FLD Curve) should
appear.
4.
Click
to transfer the FLD curve to memory.
The name FLD Curve should appear beneath Curves in memory.

5.
Click return to exit out of the FLD Curve panel.
Step 3: Reorganize the elements into two components

1.
Click Mesh > Organize > Elements > To Component and select the collectors subpanel.
2.
Click elems and select by windows from the pop-up menu.
3.
Draw a window on the graphics area to include the top half of the elements of the entire model. Refer to
the image below.
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4.
Click select entities. Notice the elements within the window are highlighted.
5.
Click Dest Component = and select comp1.
6.
Click move. All selected elements are moved and stored in the comp1 component.
7.
Repeat steps 1-6 and relocate lower elements into the comp2 component.
8.
Click return.
Step 4: Assign different thicknesses and FLC curves

1.
2.
Click component: and select comp1.
3.
Click material and select CRDQ steel.
4.
Click thickness = and type 1.0.
5.
Click update.
Notice the message bar shows "The component has been updated." You have associated the comp1
component with the CRDQ steel material and a thickness of 1.0.
6.
Repeat steps 1- 5 and re-associate the comp2 component as shown in the table below:
Component 1
Component 2
Name : comp1
Name : comp2
Material : CRDQ Steel
Material : Steel 1
FLD curve : Default_FLC (Blank)
FLD curve : FLD curve
Thickness : 1.0
Thickness : 2.0
Color : color green
Color : color blue
Note:
comp1 is assigned the Default_FLC curve (blank) and comp2 is assigned the user defined FLD
curve
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7.
Click return.
Step 5: Run the analysis and post-process the results

1.
2.
Browse for a user defined location and name the file as laser_weld_complete.hf.and click Save.
3.
From the Setup menu, click Run Analysis.
4.
Click run analysis.
5.
Click load results.
6.
From the Utility Menu, under Results, use all the functionalities for reviewing results.
7.
Review the results of the laser-welded blank.
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This feature allows you to track a line between the stamped part and the initial undeformed blank to minimize
material waste (part to blank). It also allows you to map trim lines between the intermediate stages of
stamping such as between the final flanged stage and the prior drawn stage (part to part).
The tutorial is divided into two exercises:
Exercise 1: Trimming the Line Layout
In this exercise, you will study the difference between the final part to the undeformed blank and generate
IGES data for a trim line selected from the part and mapped onto original blank.
Exercise 2: Mapping the Trim Line from Final Part to Intermediate
The purpose of the part-to-part line mapping is to allow you to map a line (or node list) between a final
part and an intermediate part.
This tutorial uses the line mapping panel.
Exercise 1: Trimming the Line Layout

This exercise uses the model file part_blanktrimline.hf

1.
2.
Browse to the file

<installation_directory>\tutorials\mfs\hf\1Step\part_blanktrimline.hf.
3.
Click Open.
Step 2: Save the file and load the result

1.
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2.
Browse for a user defined location and name the file as part_blanktrimline_complete.hf.and
click Save.
3.
4.
Click run analysis.

Notice that HyperForm is solving the analysis.
5.
When the analysis is finished, click load results.
6.
Step 3: Map the trim line on the blank

1.
From the main panel area, select the Line Mapping panel and the part to blank subpanel.
2.
Click line and select the line on the final part shape as shown in the figure.
Note:
This line is the one that will be mapped on to the flat blank.
3.
Click comps and select final_part as your flange part:.
4.
Click initial to display the original points with respect to the undeformed blank.
5.
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Note:
The trim line can be exported as IGES data externally.
Exercise 2: Map the trim line from the final part to the
intermediate part
This exercise uses the model file part_parttrimline.hf
The purpose of the part-to-part line mapping is to allow you to map a line (or node list) between a final part
and an intermediate part. This method can be useful for predicting where a part should be trimmed prior to a
flanging operation.
For example, if you have a part that is made using three operations (1st draw, trim, and 2nd draw), and you
want to predict where the flange line should be trimmed prior to the 2nd draw, you can use the line mapping
(part to part) feature. To do this, you will need to model the part shape at the end of the 1st draw
(intermediate shape) and at the end of the 2nd draw (final shape). Both of these parts should be modeled in
the same HyperForm file. After performing the 1Step analysis and loading the results file, the line mapping
function can be used. The flange line should be defined on the final shape and trim part elements should
belong to the intermediate part.
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Step 1: Retrieve the file

1.
2.
Browse the to file

<installation_directory>\tutorials\mfs\hf\1Step\part_parttrimline.hf
3.
Click Open.
Step 2: Review model setup

1.
Click Setup > Components to review the two components.

Note:
2.
You have two components that represent the intermediate and the final part.
(optional) Click the letter D to open the Display panel. Change the entity selection to loadcols to see
how the parts have been constrained.
Note:
This prevents the parts from moving with respect to each other.
Step 3: Save the file and load the result

1.
2.
Browse for a user defined location and name the file part_parttrimline_complete.hf.and click
Save.
3.
4.
Click run analysis.
5.
When the analysis is finished, click load results.
6.
Click return.
Step 4: Map the trim line

1.
From the main panel area, select the Line Mapping panel and select the part to part option.
2.
Pick the nodes or line you want to map as your flange line.
You can select the line in the ^feature component.
3.
Click trim: comps and select the intermediate_part component.
4.
Click flange part: comps and select final_part component.
5.
Click map.
Notice a mapped line is generated and stored in the ^Mapping_line component.
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Line mapping Part to Part
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The following tutorials are available:
HF-3000: Introduction to Incremental

HF-3030: Drawbead
HF-3040: Springback
HF-3050: Trimming
HF-3060: Gravity
HF-3070: Redraw
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HF-3000: Introduction to Incremental_Radioss and

Incremental_Dyna
In this tutorial, you will learn the fundamentals of Incremental_Radioss and Incremental_LsDyna using
HyperForm.
Tools
The table below lists the tools used in Incremental_Radioss and Incremental_LsDyna analysis:
Tool
Function
Sections panel
Creates section properties for a component and define the corresponding

thickness
Materials panel
Creates the material properties for a rigid tool or a deformable blank

Creates a hardening curve corresponding to the stress-strain behavior of
the deformable blank based on a power law or as a set of points from an
external file
Components panel
Creates a component and prescribe the corresponding elements, section

and material properties. A toggle switch enables adaptive meshing for a
deforming blank if required.
Loadcols panel
Creates a load collector that may hold applied velocities, forces, or

constraint conditions
Curves panel
Creates a curve by inputting the data in the available fields or by reading

an external file
Reviews or modifies any curve inside the current model using the internal
function
Tool Build panel
Several tool creation and positioning options: The auto build/setup

function automatically creates additional tools by offsetting, creates
material definitions, creates contact definitions and auto positions the
tools. The tool offset function creates a new mesh component by
offsetting elements of another. The auto position function positions two or
more components until they are just in contact.
Tool Motion panel
Allows you to prescribe the motion of the tools. It automatically calculates

the velocity curve and termination time for a moving tool based on its
expected travel and maximum velocity. The history function automatically
calculates a time step for a stable and accurate solution and also allows
you to prescribe the intervals at which the results are output.
Tool Loads panel
Allows you to prescribe a force to a specified rigid tool. In
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Incremental_LsDyna, it allows you to choose rigid body stoppers to limit

the displacement and velocity in order to minimize the inertial effects for
the rigid tool under a specified force.
Drawbeads panel
Allows you to set up analytical drawbeads that create restraining condition

during stamping. The inputs for the drawbead forces can either be numbers
corresponding to the restraining and closure force or you can just
prescribe it as a percent of the locking force.
The calculate function computes analytically, the restraining, closure and
locking force as well as the geometry that causes locking based on a
prescribed drawbead geometry, material properties and friction conditions
for the deforming blank.
136
Contacts panel
Allows you to set up contact condition between a single pair of

components or multiple sets of components.
Penetration panel
Allows you to check components for contact surface penetrations. It also

allows you to determine how much penetration is occurring and move the
penetrating nodes in order to eliminate the penetration.
Advanced panel
Allows you to set up advanced forming processes. Trimming and

springback can be setup in the Incremental_Radioss user profile. Gravity,
springback, trimming, coarsening, and mapping can be setup in
Incremental_LsDyna profile.
Run Analysis panel
Allows you to automatically create the input file and interactively submit
the job for a Radioss/Ls-Dyna analysis. A summary sheet can be invoked
which will show a brief overview of the input data. A preview animation of
the tool motion is possible from this panel. An option to write out a sta/
dynain file with the mesh and adaptivity data as well as thickness,
stresses and plastic strain can be toggled from this panel.
Load Result panel
Allows you to automatically invoke HyperView for visualizing the results

corresponding to the current model. HyperView is a high performance
visualization tool with a multitude of features to help review metal forming
analysis results.
Auto Process
Macros for automation of stamping process setup. All the

Incremental_Radioss and Incremental_LsDyna forming processes can be
easily set up and reviewed.
Multi-stage Manager
Macros for automation of multi-stage forming process set up.
HyperMorph
The HyperMorph module allows users to alter models in useful, logical,

and intuitive ways while keeping mesh distortion to a minimum. Any
morphed operation can be saved as shape entities for performing shape
optimizations afterwards.

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HyperStudy
An integrated optimization, DOE, and robustness engine. All forming

analysis result can directly transferred to HyperStudy. Hyperstudy in the
Incremental_Radioss user profile can be accessed from Applications
menu.
Process Manager
Pre-defined standard work processes. It enables you to rapidly develop

and deploy process automation applications for standard product
engineering practices within the HyperWorks environment.
Section 1: Introduction to Incremental_Radioss and

Incremental_LsDyna Forming Analysis
This section introduces the HyperForm Incremental Interface for setting up an incremental metalforming
analysis using Radioss / Dyna.
The HyperForm Incremental_Radioss user profile provides a customized interface to set up an incremental
metal forming analysis using RADIOSS,and the Incremental_LsDyna profile provides a customized interface
to set up an incremental metal forming analysis using LS-DYNA.
You can accurately model forming processes. Instead of modeling just the final part shape, as in One-Step
metal forming analysis, this uses a more rigorous modeling approach. As the name implies, small solution
steps or increments are taken to solve the problem. In this way, the incremental method allows you to
accurately model important metal forming processes (for example: binderwrap, single or multi-stage forming,
trimming, and springback). Solving a problem incrementally allows you to detect the stage at which the
process defects (for example: wrinkles, thinning or tears) occur in the blank. You can then take corrective
action to eliminate these defects by modifying the process in various ways (for example: changing tool loads,
tool motion, or tool shape). The Incremental method allows you to represent all tool surfaces, prescribe the
tool motions, apply tool loads, define material properties of the blank, and model the contact interaction
between the tools and the blank.
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Section 2: The interface

The Incremental_Radioss and Incremental_LsDyna user profiles support incremental metal forming analysis
using the RADIOSS and LS-DYNA solver. Panels help set up the following input conditions for an
incremental analysis in a highly automated fashion. You can define:
Input parameters, such as material properties for a deforming blank
The relative position and contact condition of the stamping tools
Process conditions such as tool kinematics, drawbeads. and blankholder tonnage
Automatic process for multi stage forming operations
Optimization
Result evaluation and mapping
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Incremental_Radioss panel
Section 3: Process Macros
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Application
All the incremental macros are located on the Radioss & Dyna page of the macro area (lower-right-hand side
of the HyperForm window). These macros allow you to more easily setup different application types, such
as:
Form 1st forming operation setup
Multi 2nd or nth forming operation setup
Trim Trimming operation setup
Coarse Coarsening of blank mesh setup
Sprbk Springback setup
Grav Gravity setup
Bend Tube bending setup
Hydro Hydro forming operation setup
Blank Optimizer Generate a new blank shape based on the applied deviation represented by a
reference trim line
Model
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Macro panels are used to load model, remove holes and mesh tool (R-Mesh) and blank (B-Mesh)
Setup
The setup process will change according to the application type chosen. The sequence of tasks starts from
the top and guides you through each step included in the specific application type. Further explanation of
each application type will be provided in later chapters
Results
Allows users to generate a report in selected types and styles. Advance report can allow user to interactively
zoom in, animate, rotate and contour plot a model in Microsoft PowerPoint.
Return to Incremental_Radioss Tutorials
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In this tutorial, you will learn about Auto Process . This macro allows you to set up a model for incremental
stamping simulation for RADIOSS/LS-DYNA with a minimal amount of input.
The Auto Process panel leads you through two major steps: Setup and Detail
Setup
The first step is to select the analysis type, and specify the essential input parameters for the
analysis in the fields that are available in the dialog. The blank and tools of the forming process
have fields to fill in the different values for each of these. After you have provided the required
data, you can click the Auto Position button to automatically adjust the position of the tools.
The Apply button saves the current tool and blank settings, generate load curves and create the
input files for Radioss solver. After the process is defined, you can verify that the tool motion is
correctly defined by reviewing animation control.
Details
Review the setup, and make modifications to the input data.
This tutorial assumes that you are familiar with basic HyperMesh functionality such as geometry cleanup,
meshing, and mesh editing. If you need help on these topics, please refer to the corresponding HyperMesh
tutorials in the online help.
This tutorial includes the following exercises:
Exercise 1: Set Up the Model for an Incremental Analysis
Exercise 2: Review Process Setup Details
Exercise 3: Run the Analysis
Tools
This tutorial uses the Auto Process macro, which is available in the Incremental_Radioss and
Incremental_LsDyna user profiles. This macro appears in the Tools menu.
Note:
You can choose to set up the simulation either in Radioss or Dyna. However you should not switch
between Radioss and Dyna in the middle of the set up.
To setup an analysis for Dyna, the methodology is similar to the one described below. You will
need to use the Incremental_LsDyna user profile.

This exercise uses the model file, forming_autoprocess.hf. Details about reviewing this model will be
discussed later in this chapter.
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Step 1: Load the file

1.
2.
Browse to the file

<installation_directory>\tutorials\mfs\hf\incremental\forming_autoprocess.
hf.
3.
Click Open.
Step 2: Open and review the Auto Process macro

1.
Click on the Single Action Draw

message that displays.
icon located above the graphics area. Click OK to the error
The Autoprocess macro with the default settings is displayed, as shown below.
Note:
The current forming process type is set to Double Action Draw, which is the default. This setting can
be changed according to your needs inside the macro.
Components are recognized if the names are identical (or have common letters) to the tool
nomenclature in the macro. (Blank, Die, Punch and Binder).
The colors of the components are picked up by the schematic of Single Action Draw inside of Auto
Process.
Parts that are not recognized appear with dashed lines within the Auto Process image.
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Step 3: Position the die, punch, binder, and blank

1.
Check to ensure that the Process field is set to Single Action Draw.
2.
For Draw beads: select No.
3.
For Symmetry/Constraints: select x (Symmetric to YZ plane).
4.
For Draw direction: select z.

Note: In single action draw, the die closes in by following the negative Z direction.
5.
For Motion type:, select Velocity.

Note: Tool motion will be described using velocity rather than displacement.
6.
Verify that the file type in the Source column next to Blank1, Die, Punch and Binder is HF. (You have
two options: HF and Geometry file. For Blank1, in addition, you have the STATE file. )
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7.
Use the pull down selector

in the Component column to pick sheet for the Blank1 field; Top for
the Die field; Punch for the Punch field and Binder for the Binder field.
Notice the components are recognized with solid line in the Auto Process image.
8.
Click on the Autoposition button.
9.
In the warning dialog that appears, click Proceed and then click Apply to use the tool travel values
calculated by the utility.
To use values that are user-defined, click Cancel. Click on the tool names under the Name column to
activate the column headings for the selected tool and enter the desired values in the travel fields. Click
Apply.
Step 4: Review blank parameters

1.
Click the space next to Blank1 to activate the arrow

the blank component.
2.
Define material and thickness for the blank with the following:
. This enables you to modify all parameters within
Material: Associated material to the blank (default CRDQ steel)
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Thickness: Blank thickness in (mm). Enter 1.0.

3.
Click on the Autoposition button.
4.
Note that:
Travel distances are calculated and the respective boxes are populated accordingly.
All tools are moved to appropriate locations so that they just touch the blank, as shown in the image
below.
Note:
In order to use your own values for tool travel and velocity, simply edit the values in the respective
boxes and click the Apply button without clicking Autoposition.
Step 5: Review die parameters

1.
Click the space next to Die to activate the arrow

Die component motion setup.
This enables you to modify all parameters within the
Travel 1: The distance the die travels towards the binder (mm)
Velocity 1: The velocity at which the die travels towards the binder. The suggested velocity is 4000
mm/s.
Travel 2: The distance the die travels towards the punch (mm). Enter 70.0.
Velocity 2: The velocity at which the die travels towards the punch. The suggested velocity is 10000
mm/s.
Step 6: Review punch parameters

1.
Click the space next to Punch to activate the arrow

Punch component.
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This enables you to modify all parameters within

147
Clearance: The distance between the punch and the blank at the initial configuration. Leave it set
at 0.0.
Step 7: Review binder parameters

1.
Click the space next to Binder to activate the arrow

Binder component.
This enables you to modify all parameters within
Type: The type can be either Force, or Gap:

Force: In this method, a force is applied to keep the binder closed.
Gap: Gap (mm) is defined as the actual physical distance between the binder and die that is
maintained after the binder closure until the draw is completed, after subtracting the blank thickness.
2.
Select the type as Force, and in the Force field, type 100000.
Step 8: Assign and review materials

1.
148
Click on the Blank1 line again. Click on the open folder icon
database, as shown below:
under Material to open the material

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2.
Click CRDQ in the steel folder.

The material data is shown in RADIOSS keyword format along with a curve that corresponds to the
stress/strain data. Click the Select button to make the selection.
Notes:
You can maintain a custom material database. To do so, create the data in RADIOSS keyword format
and copy it to:
<HyperWorks>\hm\scripts\hyperform\automation\materialdb\materials\steel
To define a user material library for incremental runs, define the following cards:
/BEGIN, /UNIT, /MAT, /FUNCT and /END
3.
(Optional) Use any text editor to open and review CRDQ material data in the library.
<HyperWorks>\hm\scripts\hyperform\automation\materialdb\materials\steel\CRD
Q.rad
#RADIOSS STARTER
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##==================================================================
##
## Radioss Input Deck Generated by HyperMesh Version
: 10.0
## Generated using HyperMesh-Radioss Template Version : 10.0

## Date: 01-30-2009
Time: 17:56:28
##
##==================================================================
/BEGIN
CRDQ.rad
51
##
##
/UNIT/MASS/1.0
/UNIT/LENGTH/1.0
/UNIT/TIME/1.0
##-----------------------------------------------------------------## Material Law No 43 HILL ORTHOTROPIC (Plasticity defined by a user function)
##-----------------------------------------------------------------/MAT/HILL_TAB/1
CRDQ
7.80000000000000E-09
210000.0
0.3
1.6
1.6
1.6
0.0
1
##-----------------------------------------------------------------## Functions
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##-----------------------------------------------------------------##HWCOLOR curves 1 11
/FUNCT/1
crdq_stress_strain
0.0
185.0
0.05
293.188135
0.1
339.127251
##-----------------------------------------------------------------## End Of Radioss Block Deck

##-----------------------------------------------------------------/END
4.
Step 9: Model analytical drawbeads using the Drawbeads Editor

When Draw beads: is set to yes within the Auto Process macro, you can launch the Drawbeads Editor
using the
button. The Drawbeads Editor helps you quickly create analytical
drawbeads from lines and rapidly manipulate them. You can also edit drawbeads created by clicking on the
graphics area.
1.
Within the Auto Process macro, next to Draw beads:, select Yes, which will create the Draw Beads
row in the table.
2.
Click the button
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. This launches the Drawbeads Editor tool.

151
The following tools are available on the Drawbeads Editor toolbar:

Button
Function
In the drop-down menu, select Both to display both the drawbeads and lines
in the model representation, Drawbeads to display only the drawbeads in the
model representation, or Lines to display only the lines in the model
representation.
Create a drawbead by clicking points to define the line. When the points are
in place, right-click to set the line and create a corresponding drawbead
based on the line.
Click to add a drawbead to the table. Then complete the fields for the row in
the table to define the drawbead.
Click lines to select them. Lines appear as blue dashes. When they are
selected, they become yellow.
Click to add a drawbead for each line.
Click to delete the active drawbead from the table. The active drawbead in the
table has a gray arrow next to it.
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Click to delete all drawbeads.
Click on a drawbead in the model to select it.

Click a drawbead to select it and then click and drag endpoints to change the
size of the drawbead.
Click a point on a drawbead to split the drawbead into two drawbeads at that
location.
Click two drawbeads when the button is selected to combine them into a
single drawbead.
Click the button to undo the last action in the Drawbeads Editor. You can
also right-click to sequentially remove the most recently created points.
In the drop-down menu, select:
Force to set the force calculation mode as the default, which requires that
you supply values for restraining and closure forces. You can also use the
Drawbead Calculator to determine values.
or
%-lock to set the force calculation mode as percent lock, which applies force
as a percentage of the required necking force.
Click to fit the model to the current window size.
Zoom feature. Click once to fit the model in the window. Click and drag to
draw a rectangle to zoom in on that selection area.
Click and drag to move the viewing area when the model is zoomed in.
4.
Click the pencil button
5.
Graphically draw a blue line on simplified graphical representation of the model in the top area of the
Drawbeads Editor, as shown below.
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6.
After selecting the points, click the create button to complete the first line. Notice the color is changed
to yellow and the drawbead table displayed.
7.
Repeat the same steps to create DB2 and DB3 as shown below.
8.
Click on the space left next to DB1. Notice the corresponding drawbead line is changed from green to
yellow in graphics region.
9.
Click on the button

after the Tstart column in the same row as DB1. This will open the Drawbead
Calculator as shown below.
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10. Accept the current settings and click

. Notice all the resultant conditions are calculated for the
given geometry, blank material, and thickness.
11. Click Back.

Notice calculated restraining force and normal force are automatically filled in.
12. In the Drawbeads Editor, follow the same steps for DB2 and DB3 to input values for all drawbeads.
13. Click the Update button to create the force curves for the drawbeads.
14. Click the Back button to return to the Auto Process setup page.
15. From within the Auto Process macro, click Apply.
Note:
In the Model Browser, expand the Component folder. You will find three components: ^db_line
for DB1, ^db_line for Db2 and ^db_line for DB3. These components are generated
automatically, and correspond to the three drawbeads.
Step 10: Review the animation control

The Animation Control field makes it possible to verify that the motion is setup correctly. Click the arrow
buttons to move forward or back through the process, and observe how the tools move with respect to the
blank in the graphics area.
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1.
From the Auto Process macro module, click
in the animation control field to visualize the tool
positions at the termination of the forming stage.

2.
Click
to get the model position back to initial configuration.
Exercise 2: Review in Input Data

Step 1: Review items on the Details tab
1.
Click the Details tab.
2.
Click the selector and change to All.
Note: You can select any option to review.

3.
From the Select field, select Die.

You can review the attributes of the die by clicking each item in the tree.
4.
In the die attribute tree, review the Velocity Curve as shown in the image below.
5.
The curve is displayed on the right hand side and the values are editable. Click the Preview button to
preview the new curve after editing and then click on the Apply button to accept the new curve.
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This picture show s the velocity curve for die.
6.
From the Select field, select Summary.
7.
Click Motion Summary.
8.
Click Force Summary.
9.
From the Select field, select Control.
10. Click on each tree selection and review each topic.
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11. Click Animation: Count: from the tree selection.

12. Click the selector
next to Animation:.
Notice that there are two types result requests:

Count: Number of rust types that is desired
TFreq: At different time intervals till the end of the simulation .
Exercise 3: Save the File and Run the Analysis

1.
From Auto Process, click Run to start the analysis.
2.
When the Save as window appears, save the file name as forming_autoprocess_complete.
Note: This will write out a D00 and D01 file and launch the Radioss solver.
3.
4.
Save the file as forming_autoprocess_complete.hf.
Return to Incremental_Radioss Tutorials
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User Process is a utility that allows you to setup an arbitrary stamping process from scratch. Some of the
benefits of User Process are:
the ability to set up a unique forming process. The process can be saved as a template that can be
retrieved and reapplied with no input or minimal input for a successive setup
the flexibility to include any number of tools
different orientation of the tools possible
tool kinematics that don't need to follow the conventional forming types, such as Single Action Draw,
Double Action Draw, etc.
When a model is setup in Auto Process, the model definition is captured by User Process as well.

This exercise uses the model file forming_autoprocess.hf.

1.
Click on
and browse the directories to find the file:
<installation_directory>\tutorials\mfs\hf\incremental\forming_autoprocess.
hf.
2.
Double click on the file to load it into the session.
Step 2: Define process parameters

1.
In the User Process tab, adjust the settings as described below:
2.
Right click on Symmetry and select X.
3.
Double click on Animation: Count and change the Count: value to 15.
4.
Leave the Draw direction: field at Z.
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5.
Leave the Motion Mode: field set to Velocity.
6.
Leave the Memory Mode: field set to Automatic.
7.
Right-click on Adaptivity: and select On.
Step 3: Set up the blank parameters

Complete the steps below to set up the blank parameters. Use the switch type option to make the
component as blank type as explained below
1.
Under the Tools header, right click on Sheet, select Switch type and select Blank as shown in figure
below. This will make the sheet component appear below Blanks in the User Process tab.
2.
Under the Blanks heading, right-click on Material and select Database. The Material Database
dialog will display.
3.
In the Steel folder, click on CRDQ and click Select.

The material data is shown in Radioss keyword format along with a curve that corresponds to the stress/
strain data.
Notes:
You can maintain a custom material database. To do so, create the data in Radioss keyword format and
copy it to:
<HyperWorks>\hm\scripts\hyperform\automation\materialdb\materials\steel
To define a user material library for incremental runs, define the following cards:
/BEGIN, /UNIT, /MAT, /FUNCT and /END
(Optional) Use any text editor to open and review CRDQ material data in the library.
<HyperWorks>\hm\scripts\hyperform\automation\materialdb\materials\steel\CRD
Q.rad
#RADIOSS STARTER
##
## Radioss Input Deck Generated by HyperMesh Version
: 8.0SR1
## Generated using HyperMesh-Radioss Template Version : 8.0sr1
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## Date: 08-07-2007
Time: 17:56:28
##
##==================================================================
/BEGIN
CRDQ.rad
51
##
##
/UNIT/MASS/1.0
/UNIT/LENGTH/1.0
/UNIT/TIME/1.0
##-----------------------------------------------------------------## Material Law No 43 HILL ORTHOTROPIC (Plasticity defined by a user function)
##-----------------------------------------------------------------/MAT/HILL_TAB/1
CRDQ
7.80000000000000E-09
210000.0
0.3
1.6
1.6
1.6
0.0
1
##-----------------------------------------------------------------## Functions
##-----------------------------------------------------------------##HWCOLOR curves 1 11
/FUNCT/1
crdq_stress_strain
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0.0
185.0
0.05
293.188135
0.1
339.127251
##-----------------------------------------------------------------## End Of Radioss Block Deck

##-----------------------------------------------------------------/END
Note:
4.
An easy way to create your own material would be to substitute your data into an existing
material and save it under a new name
In the User Process tab, double click on Thickness: 1.0 and change the value to 1.5.
Step 4: Set up the tools parameters

The Die in this exercise is named Top.
1.
Use the switch option to ensure this component is set as tool type.
2.
Under the component Top, right-click Contacts, select New Contact and sheet as shown in figure
below. This will create a contact between the blank and the tool named Top.
3.
Right click on the Position and select Above as shown in the figure below:
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4.
Right click on Loads: and select New Motion as shown below.
5.
Double click on Motion: Motion1 to make it editable. Rename it as Punch_Motion1.
6.
Right click on Mating Part and select Binder as shown in the figure below.
7.
Right click on Loads: and select New Motion. Double click on Motion: Motion1 to make it editable.
Rename it as Punch_Motion2.
8.
Right click on Punch_Motion2 and select Properties as shown below.
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10. Select options as shown below in the Details tab of Properties dialog and click OK.
11. Right-click on the component name Binder and make sure that Switch type is set as Tool.
12. Under the component Binder, right-click Contacts and select New Contact and select sheet. This will
create a contact between the blank and the Binder.
13. Right click on Position and select Below.
14. Right click on Loads: and select New Motion. Double click on Motion: Motion1 to make it editable.
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Rename it as Binder_Motion.
15. Right click on Binder_Motion and select Properties.
16. Select options as shown below in the Details tab of Properties dialog that pops up and click OK.
17. Right-click on the component name Punch and make sure that the Switch type is set to Tool.
18. Under the component Punch, right-click Contacts and select New Contact and select sheet. This will
create a contact between the blank and the Punch component.
19. Right-click on Position and select Below.
Step 5: Model analytical drawbeads using the Drawbead Editor

1.
From the User Process tab, right-click on Drawbeads and select Edit Drawbeads....
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Drawbeads Editor Toolbar

The following tools are available on the Drawbeads Editor toolbar.
Button
Function
In the drop-down menu, select Both to display both the drawbeads and lines
in the model representation, Drawbeads to display only the drawbeads in
the model representation, or Lines to display only the lines in the model
representation.
Create a drawbead by clicking points to define the line. When the points are
in place, click Create to set the line and create a corresponding drawbead
based on the line.
Click to add a drawbead to the table. Then complete the fields for the row in
the table to define the drawbead.
Click lines to select them. Lines appear as blue dashes. When they are
selected, they become yellow.
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Click to add a drawbead for each line.

Click to delete the active drawbead from the table. The active drawbead in
the table has a gray arrow next to it.
Click to delete all drawbeads.
Click on a drawbead in the model to select it.
Click a drawbead to select it and then click and drag endpoints to change
the size of the drawbead.
Click a point on a drawbead to split the drawbead into two drawbeads at that
location.
Click two when the button is selected to combine them into a single
drawbead.
Click the button to undo the last action in the Drawbeads Editor.
In the drop-down menu, select:
Force to set the force calculation mode as the default, which requires that
you supply values for restraining and closure forces. You can also use the
Drawbead Calculator to determine values.
or
%-lock to set the force calculation mode as percent lock, which applies
force as a percentage of the required necking force.
Click to fit the model to the current window size.
Zoom feature. Click once to fit the model in the window. Click and drag to
draw a rectangle to zoom in on that selection area.
Click and drag to move the viewing area when the model is zoomed in.
2.
Click the pencil button
3.
Graphically draw a blue line on simplified graphical representation of the model in the top area of the
Drawbeads Editor, as shown below.
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4.
After selecting the points, click the create button to complete the first line. Notice the color is changed
to yellow and the drawbead table is displayed.
5.
Repeat steps 2- 4 to create DB2 and DB3 as shown below.
6.
Click on the space left of DB1 under the Name column. Notice that an arrow appears and the
corresponding drawbead line is changed from green to yellow in graphics region.
7.
Click on the button

after the Tstart column in the same row as DB1. This opens the Drawbead
Calculator, as shown below.
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8.
Accept the current settings and click

. Notice all the resultant conditions are calculated for the given
geometry, blank material, and thickness.
9.
Click Back.
Notice calculated restraining force and normal force are automatically filled in.
10. In the Drawbeads Editor, follow the same steps for DB2 and DB3 to input values for all drawbeads.
11. Click the Update button to create the force curves for the drawbeads.
12. Click the Back button to return to close the Drawbeads Editor.
Note:
In the Model Browser, expand the Components folder. You will find three components: ^db_line
for DB1, ^db_line for Db2 and ^db_line for DB3. These components are generated
automatically, and correspond to the three drawbeads.
Step 6: Prepare the model to run

1.
Right click anywhere inside the red boundary and select Autoposition as shown below:
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The status of auto positioning is shown and updated at the left hand bottom corner of the window. Done
indicates that tools have been successfully positioned with respect to blank.
2.
Right click any where in the red boundary as shown in the above figure and select Create Input. This will
create a Radioss input deck which consists of 2 files:
<file name>_0000.rad and <file name>_0001.rad
3.
Under Binder, and under Loads, double-click on the Distance: field to make it editable. Enter -70 as a
new value.
4.
Right click any where in the red boundary as shown in the above figure and select Check Model. This
will check the model for any errors. This option also brings up a box which has
The Sequence tab will show the tool kinematics sequence
The Messages tab will show errors in the setup, if any.
Preview animation of the tool kinematics
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5.
Click on the Binder motion curve block to highlight the border with thick black line.
6.
Click and drag the thick black border line to change the tool motion interactively.
7.
In the figure below, the Binder motion curve block is dragged to start at a different time. Notice the
change in the end time from the original 0.00928 to 0.0105 as shown in the red box on the right hand
bottom corner in the picture below.
8.
After modifying the curve, use the Create input option as explained in step 2 to update the curves in the
input file.
9.
Right click any where in the red boundary as shown in the figure under point 1 and select Export to
export the D00 <file name>_0000.rad and <file name>_0001.radD01 file. Run will
generate <file name>_0000.rad, <file name>_0001.rad D00 D01 files and run Radioss.
10. Right click on Process and select the Save As Process option as shown below:
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11. Enter User_Process in the file browser and click on Save.
Exercise 2: Retrieve the Saved Process to Setup a Second Model

This exercise will make use of the model Forming_ReUse_User_Process.hf
Step 1: Load the HyperForm file

1.
Click on File and select Save As to save the existing file in the session
2.
Click on the New .hm File icon

. This deletes the existing model from the session. Note that the
parameters under the process tree is empty
3.
Click on Open Folder icon

click to open the file.
4.
Right click on Process and select Load Process as shown below.
5.
Browse for the file User_Process.up and double-click the file. A dialogue box appears as shown
below. Click OK to bring the process file into HyperForm session.
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Notice that the process tree gets populated as per the settings of the imported process file.
Step 2: Set up a second stamping model using the retrieved process file
The model and the retrieved process in the session look as below:
1.
Right click on Symmetry and select No.
2.
Right click on the component name Sheet and select Component and select Part.
3.
Right click on the component named Top and select Component and select Die.
4.
Right click on the component named Die and select Component and select Binder.
5.
Right click on the component named Punch and select Component and select Punch.
6.
Follow points 1 through 6 of step 5 from Exercise 1 to Autoposition, create input, export and run the
model.
Return to Incremental Tutorials
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This tutorial will take you through the process of setting up a multi stage simulation from within the User
Process tab.
To complete this tutorial, you should have HyperForm opened with the Incremental_Radioss user profile
loaded. This exercise uses the model file multistage_gravity_radioss.hf.
Step 1: Set the root directory and enable the Multi Step option
1.
In the User Process tab, right click on Process: Default Process and select MultiStep > Enable as
shown below:
2.
Right-click on Base Directory: and select set to select the directory where you want to store the results
of forming sequence.
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A new tab named Stage 1 with a default forming template appears below the User Process tab, as
shown below. The options under this tab are similar to the User Process single stage forming setup.
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Step 2: Set up the Multi Stage simulation

The forming sequence in this example is Gravity, Double Action Draw and Trimming.
Gravity:
1.
Right click on Process Type: and select Gravity from the menu. This will load the gravity options in the
User Process tree.
2.
Right click on Stage1: Gravity and select Activate.
3.
Click File > Open and browse to the file <install_directory>/tutorials/mfs/hf/Incr/

multistage_gravity_radioss.hf
4.
Click on Gravity icon
in the toolbar.
This will open the Auto Process function with the Gravity template loaded.
5.
In the table, in the Component column, click on the drop down arrow in the Tooling row and select Die
from the list
6.
Review the default settings. Click on Autoposition, and then click on Apply.
Notice that the set up is captured by populating the options in the User Process tree.
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Double Action Draw:

7.
Right click on Stages and select Add Stage as shown
This will create a second tab named Stage 2.

8.
Right click on Stage 2: Forming and select Activate.

Notice that the gravity model settings are masked and the User Process tree becomes empty. Click on
the Stage1 tab to see the gravity model and its setup.
9.
Load the model multistage_double_action_draw_radioss.hf from the same location as

indicated in Step 2.
10. Right click on Process: multistage_double_action_draw_radioss.hf and select Load Process from the
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menu.
This will take you to a location in the installation where templates for common forming operations are
available
11. Select the file dad.up and click Open.
This populates the User Process tree with typical double action draw settings.
12. Right click on blank under Blanks and select Component > Stage 1 > Blank.
This is to tell the process to look for the blank from the previous stage.
Trim:
13. Right click on the Stages and select Add Stage.
14. Right click on Stage 3: Forming and select Activate.
15. Right click on Process type: Forming and select Trimming from the list.
16. Click on File > Import > Geometry to import the file multistage_trim_line.iges from
<install_directory>/tutorials/mfs/hf/Incr/.
17. Right click on blank under Blanks and select Component > Stage 1 > Blank.
18. Right click on Trim Lines and select Trim Outside as shown below
19. Click on the Stage 1 tab.

20. Right click on MultiStage and select Run to start the multi step forming sequence.
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This tutorial is now complete.
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In this tutorial, you will learn the basic draw forming setup procedure using a simple box forming process.
This tutorial assumes that you are familiar with basic HyperForm modeling functionalities, such as geometry
cleanup, meshing, and mesh editing. If you need help on these topics, please refer to the corresponding
tutorials in the online help.
Tools
The following options are used in this tutorial can be accessed from the Setup menu:
Sections panel
Materials panel
Components panel
Tool Build panel
Tool Motion panel
Tool Loads panel
Save panel
Run panel
Exercise: Basic Draw Forming Analysis

This exercise uses the model file forming.hf.

1.
Click on
and browse the directories to find the file
<installation_directory>\tutorials\mfs\hf\incremental\forming.hf.
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2.
Click Open.
Step 2: Create blank section properties

1.
Click Setup > Sections.
2.
In the section: field, type blank_section.
3.
In the thickness= field, type 1.0.
4.
Click card image: and select the respective card image from the list.
Note:
For Radioss select SH_ORTH as the card image.

For Dyna, select SectShll as the card image.
5.
Click create.
6.
Click return.
Step 3: Create blank material properties

1.
Click Setup > Materials.
2.
In the material: field, type CRDQ_steel.
3.
Click card image:, and select the respective card image from the list:
Note:
For Radioss, select HillOrthotropic Tabulated as the card image.

For Dyna, select TransAnsioElasticPlastic as the card image.
4.
Click import curve.
5.
In the curve: field, type stress_strain_curve.
6.
In the sigy = field, enter 185. (MPa)
7.
In the k = field, enter 550. (MPa)
8.
In the n = field, enter 0.21.
9.
Click create.
10. Click back.

11. Click create.
12. Click on add to database. A folder browser appears allowing you to browse for a folder into which the
newly created material file will be saved. This is a one time operation for every new material created, after
which you can access the material using the Material Database option under the Setup menu.
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13. Click OK to close the folder browser.

14. Click return to close the Materials panel.
Step 4: Assign section and material properties for the blank component
1.
2.
Double-click component: and select blank.
3.
Click section: and select blank_section.
4.
Click material: and select CRDQ_steel.
5.
Select the adaptive checkbox.

Note:
For Radioss:
By default a maximum of two levels of adaptivity are enabled and the initial value is
set to 0. If the starting element size in the blank is, for example, approximately 8
mm, the smallest element after maximum refinement will be approximately 2 mm.
The adaptive levels can be changed by using the Control Cards panel, and editing
the AdaptiveGlobalMesh card. The parameter to edit is LevelMax. Refer to the
RADIOSS Starter Manual for more detailed information.
For Dyna:
By default a maximum three levels of adaptivity are enabled. In Dyna, the initial level
is considered as level 1. If the starting element size in the blank is, for example,
approximately 8 mm, the smallest element after maximum refinement will be
approximately 2 mm. The adaptive levels can be changed by using the Control
Cards panel, and editing the Adaptive card. The parameter to edit is MAXLVL.
Refer to the Dyna manual for more detailed information.
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6.
Click update.
7.
Click return.
Step 5: Display only the die component

1.
In the Model Browser, expand the Component folder.
2.
Right-click on the Component folder and select Hide.
3.
Right-click on the die component and select Show. The die component appears on the screen.
Step 6: Build the punch and binder components

1.
Click Setup > Tool Setup.
2.
Select the Build and setup tool from DIE surface subpanel.
3.
For Machine Type, choose Double acting.
4.
Click on the yellow Elements button in the Binder Source: field. The element selector panel appears.
5.
6.
If necessary, click the switch to the N1, N2, N3 and B option. Pick four nodes on the binder for N1, N2,
N3 and B as shown below.
7.
Click Select entities, and then select proceed.
8.
Click Build. This will extract the punch and binder surface from the die cavity.
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9.
Click Close.
Note:
Note after execution, binder and punch components are generated. The punch offset amount is set
using the blank thickness value. The punch offset is calculated to be thickness plus 20% (Default
tolerance). In this case, it is 1.1*2.0 mm = 1.2 mm.
This Tool Build macro creates blank and tool sections and tool materials. In case these are already
created, it will be updated.
It also creates 3 contacts viz between blank-die, blank-punch and blank-binder
Step 7: Set a top view of the blank

1.
In the Model Browser, for each component, click on the mesh icon to turn the mesh display off in the
model for all components except blank.
2.
From the toolbar, click the user view
3.
Click top.
icon.
Step 8: Define symmetry plane constraints

1.
Click Setup > Symmetry Plane.
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2.
Under Select symmetry plane, select YZ.
3.
Click create.
4.
The node selector panel appears. Pick a node on the symmetric plane of the blank (right-hand edge).
5.
Click proceed.
6.
Click Close.
Step 9: Set an iso view and display all the components

1.
From the toolbar, click the user view icon.
2.
Click iso 1.
3.
Using the Model Browser, click on the mesh icons on the components to turn their display back on.
Step 10: Define the tool motion

1.
Click Setup > Tool Motion.
2.
Click moving tool and select the punch component.
3.
Verify all options (on the right-hand side) are set to

translation
velocity
linear
termination, load curve and loadcol are also checked.
4.
Click max velocity and type 5000. (mm/s)
5.
Click total travel and type 69.2. (mm)

Note
The total travel is distance the punch travels to close in on the die. This value is the distance
between the punch and die, minus the blank thickness and a tolerance (Default is set to 20% of
blank thickness). This distance between the punch and die are calculated using the Distance (F4)
panel (Try to select, identical nodes on the die and punch).
Total Travel = Distance Punch to Die (Blank thickness + 20% Blank Thickness)
Total Travel = 70.4 (1.0 + 0.2) = 69.2
6.
Click set up.
7.
Complete the following steps for Dyna only:

Click the history subpanel on the left.
Click cycles/travel and type 500. (cycles / mm of tool travel)
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Click update.
Notice timestep is changed to 4.000e-7. The following message appears: "history was updated
successfully."
Click motion.
Click update.
8.
Click return.
Step 11: Update the contact with punch motion

1.
In the Model Browser, expand the Group folder.
2.
Right click on punch_to_blank and select Card Edit.
3.
Drag the tabs all the way to the bottom as shown in red box in the image below:
4.
Click the Number of Load Collectors toggle and select 2.

This will add a second load collector selector as shown in the red box in the image below:
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5.
Click the button loadcollector_ids(2) and select loadcol_IMP-punch.
6.
Click return.
Step 12: Define the binder load

For Radioss:
1.
From the Setup menu, click Tool Load.
2.
Click tool = and select Binder.
3.
Click tool force and type -100000. (N)
4.
Under setup option: make sure both load curve and CLOAD_Collector are checked.
5.
Click setup.
6.
Click return.
For Dyna:
1.
From the Utility Menu, under Setup, click Tool Load.
2.
3.
4.
Click max velocity and enter 500. (mm/s)
5.
Click setup. The following message appears: "Tool load was set up successfully."
Note:
188
A force of 100kN is applied to the binder. A rigid body stopper limits the maximum velocity of
the binder in order to minimize inertial effects. For more information about rigid body stopper,

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refer to HyperForm's FAQ section.

6.
Click return.
Step 13: Update the contact with binder load

1.
In the Model Browser, under the Groups folder, right click on binder_to_blank and select Card Edit.
2.
Drag the tabs all the way to the bottom of their respective sections.
3.
4.
Click on the button loadcollector_ids(2) twice and select loadcol_CLOAD-binder.
5.
Click return.
Step 14: Save the analysis setup as forming_complete.hf

1.
2.
Use the file browser to save the file as forming_complete.hf.
3.
Click Save.
Step 15: Review the animation and run the analysis

For Radioss:
1.
2.
Click create sta file.

Note:
3.
At the end of the computation, Radioss will write out a file called "sta". This file contains all the
thickness, stress and strain information necessary to perform subsequent operations. This file is
essential for performing multi-stage setups.
Click animation.
Note:
4.
Animation feature enables you to review and correct the tool motion.
Click run to start the computation in Radioss.
For Dyna:
1.
From the Utility Menu, under Setup, click Run.
2.
Click create dynain.
3.
Click applied comps:comps and select blank.
4.
Click select.
5.
Select the DYNA checkbox to enable DYNAIN output.
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6.
Click setup. A message appears stating: "Dyna3d was set up successfully."

Note:
At the end of the computation, Dyna will write out a file called "dynain". This file contains all the
thickness, stress and strain information necessary to perform subsequent operations. This file
can be read directly by HyperForm and is essential for performing multi-stage setups.
7.
Click return.
8.
Click animation.
Note:
9.
This animation feature enables you to review and correct the tool motion.
Click dyna file and type forming_complete for the name.
10. Click run. A Dyna input file named forming_complete.bdf is generated. The file can be submitted
to Dyna.
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This tutorial illustrates a combined binderwrap and draw forming set up procedure. A setup file containing the
die mesh provides a starting point. All tool components are generated from the die tool mesh. Appropriate
material and section properties are assigned to each component.
In this tutorial, you will learn about:
Double action forming processes
Importing a HyperForm file
Birth and death time concepts
Tools
The following options used in this tutorial can be accessed from the Setup menu:
Sections panel
Materials panel
Comps panel
Tool Build panel
Tool Motion panel
Tool Loads panel
Save panel
Run panel
Exercise: Performing a Combined Binderwrap and Draw

Forming Analysis
This exercise uses the model file bwrap_form_Radioss.hf file for Radioss and bwrap_form_.hf file
for LsDyna and bwrap_form_blank.hf for both profiles.
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1.
Click on
<installation_directory>\tutorials\mfs\hf\incremental\bwrap_form_Radioss.hf
file for Incremental_Radioss and
<installation_directory>\tutorials\mfs\hf\incremental/bwrap_form_.hf file for
Incremental_LsDyna
2.
Double click on the file to load into the session.
Step 2: Import a second file

1.
Click the Import icon
2.
Click the Import HM Model icon

bwrap_form_blank.hf.
3.
Click Open in the dialog, and then click Import.
Note:
4.
to open the Import dialog.

and use the Open File icon
to browse to the file
Import brings the file into the current session without erasing the existing file. Load model brings
the model into the current session and will erase the existing file.
Click Close to close the Import dialog.

1.
2.
3.
In the thickness = field, type 1.0 (mm).
4.
Click card image= and select the respective card image from the list.
For Radioss, select SH_ORTH as the card image.
For Dyna, select SectShll as the card image.
5.
Click create.
6.
Click return.

1.
Click Setup > Materials. The Material definition panel displays.
2.
Click material: and enter CRDQ_steel.
3.
Click card image and select the respective card image:
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For Radioss, select HillOrthotropic Tabulated

For Dyna, select TransAnisoElasticPlastic
4.
Click import curve.
5.
Click curve: and enter stress_strain_curve.
6.
Click sigy = and enter 185 (MPa).
7.
Click k = and enter 550 (MPa).
8.
Click n = and enter 0.21.
9.
Click create.
10. Click back.

11. Click create.
12. Click on add to database. A folder browser is displayed, allowing you to browse for a folder into which
the newly created material file will be saved. This will be a one time operation for every new material
created, after which you can access the material using the Material Database option in the Setup
menu.

14. Click return to close the Materials panel.
Step 5: Assign section and material properties to the blank component

1.
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2.
3.
4.
5.
Select the adaptive checkbox.
6.
Click update.
7.
Click return.
Note:
By default, two levels of adaptivity are enabled. If the starting element size in the blank is, for
example, approximately 8 mm, the smallest element after maximum refinement will be
approximately 1 mm. The adaptive levels can be changed by using the Control Cards panel, and
editing the AdaptiveGlobalMesh card. The parameter to edit is LevelMax. Refer to the
RADIOSS Starter Manual for more detailed information.
Step 6: Display a top view of the die component only

1.
Click on the Model tab to display the Model Browser. If it is not available, click on View and select
Model Browser to display it.
2.
Expand the Component folder.
3.
Click on the mesh icon as shown in the figure below to turn off the blank mesh.
4.
On the toolbar, click the user views
icon and select top.
Step 7: Build the punch and binder

1.
From the Preferences menu, select Meshing Options.
2.
Click feature angle and enter 2.0 (degrees).
3.
Click return.
Note:
Changing the feature angle to 2.0 will make element selection on the binder area easier.
4.
From the Setup menu, select Tool Setup.
5.
Select the Build and setup tool from DIE surface subpanel.
6.
For Machine Type, choose Double acting.
7.
In the Binder Source: field, click Elements. The element selection panel is displayed.
8.
Select one element on the binder area of the die as shown below.
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Figure 1: Element to select
9.
Click elems and select by face option from the extended entity selection. This highlights all the
elements on the binder area of the die as shown below.
10. Click proceed.

11. Click Build.
12. Click Close.
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Note:
Notice after executing the build, the binder and punch components are generated. The punch offset
amount is set using the blank thickness value. The punch offset is calculated to be thickness plus
10%. In this case, it is 1.1*1.0 mm = 1.1 mm.
The Tool Build macro creates tool sections and tool materials. If these were already created, they
are updated.
This macro also creates 3 contacts viz between Blank-Die, Blank-Punch and Blank-Binder
Step 8: Define the tool motion for the binder

1.
Click Setup > Tool Motion.
2.
Click moving tool and select the binder component.
3.
Click max velocity and type 2000 (mm/s).
4.
Click total travel and type 5.7 (mm).

Note:
The total travel of the binder is the distance the binder has to travel rest on the die holding the
blank. This value is the distance between the binder and die, minus the blank thickness and a
tolerance (typically 10-20%). This distance between the binder and die are calculated using the
Distance (F4) panel. (Try to select identical nodes on the die and binder).
Total travel - Distance Binder to Die - (Blank thickness + 20% Blank Thickness)
Total travel = 6.9 - (1.0 + 0.2) = 5.7
5.
Verify all options (at right hand side) are set to

translation
velocity
linear
6.
Click set up.
7.
Click the history subpanel.

Note the calculated termination time is T = 4.850e-03 seconds. This time will be used again later in the
exercise.
8.
Click the motion subpanel.
9.
Click edit card.

For Radioss, click Tstop field and enter 4.850e-03 (s).
For Dyna, click DEATH time field and enter 4.850e-03(s).
This is the time at which the prescribed motion of the binder is killed, and is also the time at which the
force load is applied to the binder later in this exercise.
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10. Click return.

11. Click update.
Step 9: Update the contact with binder tool motion

1.
2.
Right click on binder_to_blank and select Card Edit.
3.
Scroll all the way to the bottom of the sections as shown in red box in the image below:
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5.
Click on the button loadcollector_ids(2) and select loadcol_IMP-binder.
6.
Click return.
Step 10: Define the punch tool motion

1.
Click moving tool and select the punch component.
2.
Click max velocity and enter 5000 (mm/s).
3.
Click total travel and type 76.0 (mm).

Note:
The total travel is distance the punch travels to close in on the die. This value is the distance
between the punch and the die, minus the blank thickness and a tolerance (typically 10-20%).
This distance between the punch and die are calculated using the Distance (F4) panel. (Try to
select identical nodes on the die and punch.)
Total Travel = Distance Punch to Die - (Blank thickness + 20% Blank Thickness)
Total Travel = 77.2 - (1.0 + 0.2) = 76.0
4.
Click starting time and enter 4.850e-03. (s)
5.
Select the termination check box to uncheck it.
6.
Click set up.
7.
For Incremental_Dyna only, complete the following steps:

Click cycles/travel and enter 100 (cycles/mm of tool travel).
Click update. Notice that the timestep is reduced from 4e-7 to 2e-6.
8.
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Click return.

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Step 11: Update the contact with punch tool motion

1.
In the Model Browser, under the Groups folder, right click on punch_to_blank and select Card Edit.
2.
Scroll all the way to the bottom of the sections.
3.
4.
Click on the button loadcollector_ids(2) and select loadcol_IMP-punch.
5.
Click return.

For Incremental_Radioss user profile:
1.
From the Setup menu, select Tool Load.
2.
3.
4.
Verify that load curve and CLOAD_Collector are selected.
5.
Click setup.
6.
From the Setup menu, select Curves Editor.
7.
Select the curve CLOAD_curve-binder and enter 4.450e-03 as the first entry of the X axis as shown
below:
4.450e-03
0.0
1.0
0.0
8.
Click on Update.
9.
Click on Close.
10. Click return.
For Incremental_Dyna user profile:

1.
From the Utility Menu, under Setup, click Tool Load.
2.
3.
4.
Click max velocity and type 500. (mm/s).
5.
Click birth time and type 4.450e-03 (s).

Verify that Load curve, loadrigbod and stoppers are all selected.
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6.
Click setup.
A force of 200kN is applied to the binder. A rigid body stopper limits the maximum velocity of the binder
in order to minimize inertial effects. This rigid body stopper is defined to be active (note birth time) only
after the prescribed motion of the binder has been killed. For more information about rigid body stopper,
refer to the FAQs in the HyperForm online help.
7.
Click return.

1.
2.
3.
4.
Click on the button loadcollector_ids(3) and select loadcol_CLOAD_binder.
5.
Click return.
Step 14: Update the tool type for die

1.
2.
Click component and select die.
3.
Click section and select tool_sec.
4.
Click material and select CRDQ_steel.
5.
Select the rigid checkbox.
6.
Click update.
Step 15: Save the analysis

1.
2.
Save the file as bwrap_form1_radioss_complete.hf for Radioss and

bwrap_form1_complete.hf for Dyna.
3.
Click save.

1.
From the Setup menu, select Run Analysis.
2.
Click animation.
Note: Notice the kinematics of the tool motion. This animation feature enables you to review and correct
the tool motion.
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3.
Click run to start the computation in RADIOSS.
For LS-DYNA:. An LS-DYNA input file named bwrap_form1_complete.bdf is generated. The file can be
submitted to LS-DYNA for solver analysis.
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HF-3030: Drawbead
In this tutorial, you will learn:
How to apply analytical drawbeads in a simple box forming process
How to define tool motion
About birth and death time concepts in tool motion definition
How to define tool load
Tools
The following panels are used in this tutorial and can be accessed from the Setup menu:
Sections panel
Materials panel
Comps panel
Tool Build panel
Tool Motion panel
Tool Loads panel
Save panel
Run panel
HyperForm provides two methods by which to setup analytical drawbeads:
The drawbead function, from the Setup menu of the Incremental_Radioss/Incremental_LsDyna
user profiles.
The Drawbeads Editor module, from the Setup menu of the Incremental_Radioss/
Incremental_LsDyna user profiles
Exercise: Using Analytical Drawbeads

This exercise uses the model file drawbeads_Radioss.hf and drawbead_lines.igs for Radioss
setup and drawbeads.hf and drawbeads_lines.igs for Dyna setup.
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1.
Click the
icon and browse the directories to select the file
<installation_directory>\tutorials\mfs\hf\incremental\drawbeads_radioss.hf
for Incremental_Radioss and <installation_directory>\tutorials\mfs\hf\incremental\
drawbeads.hf file for Incremental_LsDyna.
2.
Click Open.
Step 2: Translate the binder

1.
Click Mesh > Translate > Components.
2.
Click on comps and select the Binder component.
3.
Set the direction switch to z-axis.
4.
Set the toggle to magnitude = and enter 6.0.
5.
Click translate +.
6.
Click return.
Note:
The binder is translated in the z-direction to account for the addition of analytical drawbeads of
height 6.0 mm.
Step 3: Import the drawbead IGES line

1.
2.
3.
Click on the file browser icon

<installation_directory>\tutorials\mfs\hf\incremental\drawbead_lines.igs.
4.
Click Open to select the file, then click Import to import the file.
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to open the tabbed Import dialog.

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5.
Step 4: Display only the die component and change the visualization to wire frame
mode
1.
2.
Click on the mesh icon as shown in the figure below to turn off the mesh display for all components
except the blank mesh.
Display the binder and draw bead lines
3.
Click on the wireframe icon
to change the visualization to wire frame mode.
Step 5: Create analytical drawbeads

1.
Click Setup > Drawbeads.
2.
In the drawbead: field, type db1.
3.
Click comps and select the blank component as the master.
4.
Click line and select the line for DB1 as shown in the figure below.
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For Incremental_Dyna only, click attached to and select binder.
5.
Click calculate to switch to the drawbead force calculator.

Notice that Drawbead height and radius are automatically set to 6.25.
6.
Click shoulder radius and type 2.0.
7.
Ensure that Round is selected as the Drawbead type.
8.
Click calculate.
Notice that restraint force and closure force are automatically calculated.
9.
Click back to accept calculated values.
10. Click color and select a color.

11. Click create to generate the drawbead.
Notice a thick line drawn in selected color appears on the blank.
Step 6: Create additional drawbeads

1.
Click the field beside drawbead = and type db2.
2.
3.
Click line and select the line for DB2 as shown in figure 1.
4.
Click color and select a color.
5.
Click create.
6.
Click the field beside drawbead = and enter the name db3.
7.
8.
Click line and select the line for db3 as shown in the figure.
9.
10. Click create.
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11. Click return.

Note:
For Radioss:
Three components are created for drawbeads with the names ^db_line for [user input
name]. /INTER / TYPE 8/INTER ID Radioss cards are created and stored in those
components.
For Dyna:
Three components are created for drawbeads with the names ^db_line for [user input
name]. *Contact_Drawbead_Title DYNA cards are created and stored in those
components
Step 7: Display all components and set the view to Isometric

1.
In the Model Browser, click on the mesh icon as shown in the figure below to turn off the blank mesh.
2.
From the tool bar, click the user view
3.
Click Iso1.
4.
In the Model Browser, right click on the Component folder and select Show.
icon.
Step 8: Define the binder tool motion

1.
From the Setup menu, click Tool Motion.
2.
Click moving tool and select the Binder component.
3.
Click max velocity and type 2000.
4.
Click total travel and type 6.0.
5.
Verify that all options (at right-hand side) are set to:
translation
velocity
linear
6.
Click setup.
7.

Notice that the calculated termination time is T = 0.005 seconds. This time will be used again later in the
exercise.
8.
Click the motion subpanel.
9.
Click edit card.
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10. For Radioss, click Tstop field and type 0.005. For Dyna, click DEATH field and type 0.005.
This stop/death time will ensure that the prescribed motion of the binder is stopped before a force load is
applied.
11. Click return.
Stay in the Tool Motion panel for the next step.
Step 9: Update the contact with binder tool motion

1.
In the Model Browser, expand the Groups folder.
2.
Right click on Binder_to_blank and select Card Edit.
3.
Scroll all the way to the bottom of the sections as shown in red box in the image below:
4.

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5.
Click on the button loadcollector_ids(2) and select loadcol_IMP-binder.
6.
Click return.
Step 10: Define the punch tool motion

1.
Click moving tool and select the Punch component.
2.
Click starting time and type 0.005.

This start time offset will ensure that the punch does not start moving until the binder is fully closed.
3.
Click update.
4.

Note the termination time, T, is now calculated to be 2.090e-2 seconds.
For Incremental_Dyna only, complete the following steps:
Click cycles/travel and type 100.
Click update.
5.
Click return.
Step 11: Update the contact with punch tool motion

1.
In the Model Browser, under, the Groups folder, right click on punch_to_blank and select Card Edit.
2.
3.
4.
Click on the button loadcollector_ids(2) and select loadcol_IMP-punch.
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5.
Click return.
Step 12a: Define the binder load (Incremental_Radioss only)

1.
2.
3.
Click tool force and type 100000.
4.
Verify the direction is set to Z axis.
5.
Click setup.
6.
Click return.
Step 12b: Define the binder load (Incremental_LsDyna only)

1.
2.
3.
Click tool force and type 100000.
4.
Verify the direction is set to Z.
5.
Click max velocity and type 500.
6.
Click setup.
7.
Click edit beside the stoppers option checkbox.
8.
Click TB and enter 0.005. (s).
9.
Click return.
This ensures the rigid body stopper becomes active as soon as the prescribed motion of the binder is
killed.
10. Click update.

11. Click return.

1.
2.
3.
4.
Click on the button loadcollector_ids(3) and select loadcol_CLOAD_binder.
5.
Click return.
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Step 14: Save the analysis setup as drawbead_complete.hf

1.
2.
Use the file browser to save the file as drawbead_Radioss_complete.hf for Radioss and
drawbead_complete.hf for Dyna.
3.
Click Save.

For Incremental_Radioss:
1.
2.
3.
Click animation
Note:
4.
Notice the kinematics of the tool motion. This animation feature enables you to review and correct
the tool motion.
Click run to start computation in RADIOSS.
For Incremental_Dyna:
1.
From the Utility Menu, under Setup, click Run.
2.
3.
Click applied comps: comps and select blank.
4.
Click select.
5.
Select the DYNA check box.
6.
Click setup.
7.
Click return.
8.
Click animation.
Notice the kinematics of the tool motion.
9.
Click dyna file and specify the name as drawbead_complete.
10. Click run. A dyna input as drawbead_complete.bdf is generated.

The file can be submitted to LS-DYNA for solver analysis.
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HF-3040: Springback
During forming process, elasto-plastic stress gradients across the surface builds up and results in an
accumulation of residual stresses. The residual stresses cause the material to bounce back after forming.
The resultant deviations from the profile often require manual adjustment before the component is considered
acceptable for assembly. Components that do not fit in the final assembly usually need additional shimming
and assembly time.
In this tutorial, you will learn the setup procedure for performing a springback analysis for Radioss and
LsDyna. The part shape and stress and strain states at the end of a simple draw forming operation are the
inputs to setup. Appropriate material and section properties are assigned to the blank component. Fixture
constraints are applied to the part to eliminate rigid body modes.
In this tutorial, you will learn:
How to load an .hf model, including an additional *.hmx file
Section definition
Material definition
Setting up a springback analysis
Tools
The following options are used in this tutorial and can be accessed from the Setup menu:
Sections panel
Materials panel
Components panel
Advanced panel (for Radioss)
Sprbk Setup panel (for Dyna)
Exercise: Springback Exercise

This exercise uses the following model files:
springback_radioss.hf and sta_for_springback.hmx (for Radioss)
springback.hf and dynain_for_springback.hmx(for Dyna)
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Step 1: Import the file and set the Include file

The model files are zipped in the tutorial location. Before proceeding, unzip the files.
1.
Click on the open .hm file icon

<installation_directory>\tutorials\mfs\hf\incremental\springback_radioss.
hf for Radioss or
<installation_directory>\tutorials\mfs\hf\incremental\springback.hf for Dyna.
2.
Click Open.
3.
From the View menu, select Eroded Mesh to enable a clear view with only the adapted elements
displayed.
Note:
A file containing the forming results, <filename>_STA.hmx for Radioss and dynain.hmx for
Dyna, must be included in the springback analysis.To set the Include file, first copy the file
sta_for_springback.hmx from the installation directory
\tutorials\mfs\hf\incremental to the current working directory, and then follow either of
the two methods described below.
Method 1:
1.
In the Model Browser, under Master Model, right-click on the *.sta.hmx file and select Include
File Options
The Include File Options dialog appears, showing the current path of the Include file. (The current
path points towards the installation directory \tutorials\mfs\hf\Incremental)
2.
Browse for the new path and click Set. The new path is the location of the current working directory,
where the *.sta.hmx file is saved.
Method 2:
1.
Edit the D00 file, after the complete setup, and insert the card - #include <filename>
Here <filename> is sta_for_springback.hmx
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1.
From the Setup menu, select Sections.
2.
Click section: and enter blank_section.
3.
Click thickness = and enter 1.0. (mm)
4.
Click card image= and select the respective card image from the list:
For Radioss, select SH_ORTH as the card image
For Dyna, select SectShll as the card image
5.
Click create.
6.
Click return.

1.
From the Setup menu, select Materials.
2.
Click materials: and enter CRDQ_steel.
3.
Click card image: and select the respective card image from the list:
For Radioss, select HillOrthotropicTabulated as the card image
For LsDyna, select TransAnsioElasticPlastic as the card image.
4.
Click import curve.
5.
In the curve: field, enter stress_strain_curve.
6.
Click sigy = and enter 185. (MPa)
7.
Click k = and enter 550. (MPa)
8.
Click n = and enter 0.21.
9.
Click create.
10. Click back.

11. Click create.
12. Click return.
Blank material properties are defined using Hill_Orthotropic Tabulated in Radioss and a transversely
anisotropic elastic plastic material model in LsDyna. Material density, Poissons ratio, and Youngs
modulus are assumed to be that of steel. A Holloman-type stress-strain curve is created and assigned to
the material.
Alternatively, an elastic material model could be used to model the blank since the stress recover during
spring-back is essentially elastic.
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1.
From the Setup menu, select Components.
2.
Click component: and select Blank.
3.
4.
5.
Check the adaptive checkbox.
6.
Select a color.
7.
Click update.
8.
Click return.
Step 5: Set a top view of the blank

1.
From the keyboard, click the letter v.
2.
Click top.
Step 6: Set up constraints

1.
Select Setup and select Advanced. Make sure you are in the springback subpanel.
For the Incremental_LsDyna user profile, from the Utility Menu, choose Sprbk and click Sprbk Setup
. Ensure that the option using dynain is set.
2.
Click constraints: nodes and select node A as shown in the figure below.
3.
Check only the dof3.
4.
Click setup.
5.
Repeat the above procedures and create a total of three constraints as shown in image below.
6.
Press the P key to refresh the screen.
7.
Click return.
Constraint nodes are chosen to eliminate rigid body modes. Artificial stabilization is used to gradually
unload stress in the part.
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Step 7: Save the analysis setup

1.
Click on the File menu and select Save As.
2.
Save the file as springback_radioss_complete.hf for Radioss and

springback_complete_hf for Dyna.
3.
Click save.

1.
2.
3.
Click run to start the computation in Radioss.

For Radioss, <filename>_0000.rad and <filename>_0001.rad files are created and the
solver is launched.
For Dyna, springback_complete.bdf is generated. The file can be submitted to LS-DYNA for
solver analysis.
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HF-3050: Trimming
This tutorial illustrates the setup procedure for performing a trimming operation. This example uses a simple
box form. The part shape, stress, and strain state at the end of a simple draw forming operation are the
inputs for this analysis. Appropriate material and section properties are assigned to the blank component. A
trim line is imported from a file and the trimming operation is set up.
Note:
It is possible to trim by selecting the elements and by components. Trimming by components

option can trim only the elements inside the trim line.
Tools
The following options used in this tutorial can be accessed from the Setup menu. For LsDyna, the Trim
application needs to be selected.
Sections panel
Materials panel
Components panel
Advanced panel
Run Analysis panel
Exercise: Trimming Analysis

This exercise uses the model file radios_trimming_sta (for Radioss), dynain_trimming (for
LsDyna), and trim_line.igs.
Step 1: Load the STA file

1.
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2.
3.
Set the File type field to RADIOSS (Block) and browse to the file
<installation_directory>\tutorials\mfs\hf\incremental\radioss_trimming.sta
(for Radioss) and <installation_directory>\tutorials\mfs\hf\incremental/
dynain_trimming (for Dyna).
4.
Click Open to select the file, and then click Import to import the file into HyperForm.
Note:
When the STA/DYNAIN file imports, only the node and element definitions are read into
HyperForm. The adaptive constraints, initial stress and initial strain quantities are
automatically placed into a new file called Radioss_trimming.sta.hmx/dynain.hmx.
This extra information is automatically included in the new setup by use of the *INCLUDE card
for Radioss and *INCLUDE card for Dyna. The sta.hmx file and the dynain.hmx file will be
created in the working directory.
If, for some reason, you wish to change the path of the INCLUDE card, use the following
steps. Ensure that the *sta.hmx/Dynain.hmx file is copied to the changed location.
Method 1:
1.
Right-click on the *.sta.hmx/Dynain.hmx file in the Model Browser under Master

Model and select Include File Options A window will pop up showing the current
path of the file.
2.
Browse for the new path and click Set. The new path is the location of the current
working directory, where the *.sta.hmx/Dynain.hmx file is saved
Method 2:
1.
For Radioss, edit the D00 file after the complete setup, and insert the card #include
<filename>. For Dyna open the BDF file and insert the card *INCLUDE
redraw_dynain.hmx.
Here <filename> is cup_draw_0001.sta.hmx/redraw_dynain.hmx
Warning: No renumbering or rotations of the imported STA component is allowed. The stress and strain
tensors are written with respect to a global coordinate system and require a suitable
transformation. Currently, HyperForm does not support transforming these stress and strain
tensors. The STA file should be imported prior to importing other tooling models to prevent
node or element renumbering by HyperForm.
Step 2: Rename the imported component

1.
2.
Right-click on the component named 1 and select Rename.
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3.
Enter the name as blank.

1.
2.
3.
In the thickness = field, type 1.0.
4.
Click card image= and select the respective card image from the list:
For Radioss, select SH_ORTH as the card image.
For LsDyna, select SectShll as the card image.
5.
Click create.
6.
Click return.

1.
Click Setup > Materials.
2.
3.
For Radioss, select HillOrthotropicTabulated.
For LsDyna, select TransAnsioElasticPlastic.
4.
Click import curve.
5.
6.
In the sigy = field, type 185. (MPa)
7.
In the k = field, type 550. (MPa)
8.
In the n = field, type 0.21.
9.
Click create.
10. Click back.

11. Click create.
12. Click return.
Step 5: Assign section and material properties for the blank component
1.
2.
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3.
4.
5.
Select a color.
6.
Click update.
7.
Click return.
Step 6: Import the IGES file

1.
2.
3.
4.
Click Open and then click Import.
5.

to switch to Import Geometry options.
and browse to the file trim_line.igs.
Step 7: Activate geometry handles for easier graphics area line selection
1.
Click Preferences > Geometry Options.
2.
Select the graphics subpanel, and check the geom handle option.
Notice the geometry handles appear on top of all lines.
3.
Click return.
Step 8: Combine trim curve lines in a clockwise fashion

1.
Click Geometry > Edit > Lines > Combine Line.

For LsDyna, under Setup, click Combine Line.
2.
Click 1st lines and select the 1st line as shown in the image.
3.
Click 2nd line and select the 2nd line as shown in the image.
Notice two selected lines will be combined into a new line.
4.
Repeat this selection process in a clockwise direction using the new line and the next adjacent line until
all lines have been combined into a single line.
5.
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Step 9: Set up a trimming operation

1.
From the Setup menu, click Advanced and choose the trimming subpanel.
2.
Click trim part: comps and select the blank component.
3.
Click trim line: line and select the line.
4.
Click the direction selector and select z-axis.
5.
Click toggle to switch to remove element inside.
6.
Click trim.
Note: Trimming inside Radioss is done in the pre-processor.
7.
After the trimming calculation is done, from the View menu, click Trimmed Mesh. This will switch on
the trimmed mesh.
1.
Click Trimming Setup under Trim application type.
2.
Click applied comps: comps and select blank component.
3.
Click trim lines: line list and select the line.
4.
Click the direction selector and select z-axis.
5.
Click the toggle to switch to remove element inside.
6.
Click setup.
7.
Click return.
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Step 10: Save the analysis setup as trimming_complete.hf

1.
2.
Save the file as trimming_complete.hf,
3.
Click save.
Step 11: Run the analysis (Dyna profile only)

1.
Under Setup, click Run.
2.
3.
Click applied comps: comps and select blank.
4.
Click select.
5.
6.
Click setup.
7.
Click return.
8.
Click dyna file and specify the name trimming_complete
9.
Click run. A dyna input file trimming_complete.bdf is generated. The file can be submitted to LSDYNA for solver analysis.
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HF-3060: Gravity
This tutorial illustrates the setup procedure for performing a gravity analysis. A setup file containing the blank
and die mesh provides the starting point. The Auto Process utility is used to position the blank with
reference to the die, and assign the appropriate material and section properties to the tool and blank.
Tools
This tutorial uses the Gravity process available under the Auto Process utility:
Exercise: Gravity Analysis

This exercise uses the model file gravity.hf.
Step 1: Load the HyperForm setup file

1.

and browse to the file <installation_directory>/
tutorials/mfs/hf/incremental/gravity.hf.
2.
Click Open.
Step 2: Set up a Gravity process using Auto Process

1.
Click on the Gravity icon
2.
Under the component column, ensure that blank is selected for row Blank1 and tool_source is
selected for the Tooling row.
. This opens the Auto process utility with the gravity template loaded in it.
The primary purpose of simulating gravity is to compute the shape of the deformed sheet due to a gravity
load. This can help to reduce the simulated tool travel distance, and eliminates some of the low
frequency dynamic oscillation that occurs when the tools first contact the blank.
Select the implicit option (LsDyna user profile only).
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3.
Click Autoposition.
This automatically positions the blank with reference to the tool without user intervention. Avoiding initial
penetration/intersections would be considered while autopositioning.
4.
Click Apply.
5.
Click Run. Specify the file name of the input deck as gravity_complete.
<filename>_0000.rad and <file name>_0001.rad files are written and automatically
launches the RADIOSS solver.
Radioss: <filename>_0000.rad and <filename>_0001.rad files are written and
automatically launches the RADIOSS solver.
Dyna: Writes a .bdf file. This file can later be submitted into LS-DYNA.
Note:
Radioss writes a STA file and Dyna writes a dynain file, which can be used as include files for
subsequent analysis.
Step 3: Save the analysis setup as gravity_complete.hf

1.
Click File and click Save As...
2.
Enter the file name as gravity_complete.hf.
3.
Click Save.
4.
Click return.
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HF-3070: Redraw
This exercise illustrates a second stage setup procedure of a forming analysis. A setup file containing the
tool meshes provides the starting point. The blank shape at the end of the binderwrap and draw forming
exercise is used in this analysis. Appropriate material and section properties are assigned to each
component.
This tutorial assumes that you are familiar with functionalities such as creating components, geometry
cleanup, and meshing. Information about these topics can be found in the online help.
Tools
The following options used in this tutorial can be accessed from the Setup menu:
Import STA/Dynain
Rename
Sections
Materials
Tool Motion
Tool Load
Exercise: Perform a redraw forming analysis

This exercise uses the model files redraw_radioss.hf and cup_draw_001.sta for Radioss setup,
and redraw_hf and redraw_dynain for Dyna setup.
Step 1: Load the STA/DYNAIN file

1.
2.
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and make sure the File type field is set to Radioss (Block).

227
3.

to open the dialog. Change the Files of type option to all files and
browse to the file <installation_directory>\tutorials\mfs\hf\incremental\
cup_draw_0001.sta for RADIOSS BLOCK and redraw_dynain for DYNA KEY.
4.
The Import Process Messages dialog appears. You can choose to show the .hmx file, save the file with
a different name, delete the message file, or simply close the dialog. Click Close to close the dialog.
Note:
When the STA/DYNAIN file imports, only the node and element definitions are read into
HyperForm. The adaptive constraints, initial stress and initial strain quantities are
automatically placed into a new file called sta.hmx/dynain.hmx. This extra information is
automatically included in the new setup by use of the *INCLUDE card for Radioss and
*INCLUDE card for Dyna. The sta.hmx file and the dynain.hmx file will be created in the
working directory.
Warning: No renumbering or rotations of the imported dynain component is allowed. The STA/DYNAIN
file should be imported prior to import other tooling models to prevent node or element
renumbering by HyperForm.
If, for some reason, you wish to change the path of the INCLUDE card, use the following
steps. Ensure that the *sta.hmx/Dynain.hmx file is copied to the changed location.
Method 1:
1.
Right-click on the *.sta.hmx/Dynain.hmx file in the Model Browser under Master

Model and select Include File Options A window will pop up showing the current
path of the file.
2.
Browse for the new path and click Set. The new path is the location of the current
working directory, where the *.sta.hmx/Dynain.hmx file is saved
Method 2:
1.
For Radioss, edit the D00 file after the complete setup, and insert the card #include
<filename>. For Dyna open the BDF file and insert the card *INCLUDE
redraw_dynain.hmx.
Here <filename> is cup_draw_0001.sta.hmx/redraw_dynain.hmx.
Warning: No renumbering or rotations of the imported STA component is allowed. The stress and strain
tensors are written with respect to a global coordinate system and require a suitable
transformation. Currently, HyperForm does not support transforming these stress and strain
tensors. The STA file should be imported prior to importing other tooling models to prevent
node or element renumbering by HyperForm.
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Step 2: Import the file

1.
In the Import dialog, click on the Import HM Model icon
2.

. Change the Files of type option to all files and browse to the file
redraw_radioss.hf for the Radioss setup and redraw.hf for the Dyna setup.
3.
4.
Note:
Importing a HyperForm file allows this model to be added on to the previously-loaded STA/DYNAIN
model without numbering any existing IDs in the HyperForm database.
Step 3: Rename the STA/DYNAIN component

1.
2.
Right-click on the component 1 and select Rename.
3.
Enter the new name as blank.

1.
From the Setup menu, click Sections. The Section definition panel is displayed.
2.
In the section: field, enter blank_section.
3.
In the thickness: field, enter 1.0 (mm).
4.
Click card image: and select

For Radioss, select P9_SH_ORTH
For Dyna, select Sectshll
5.
Click create.
6.
Click return.

1.
From the Setup menu, click Materials. The Material definition panel displays.
2.
In the material: field, enter CRDQ_steel.
3.
Click card image and select the respective card image from the list:
For Dyna, select TransAnisoElasticPlastic
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4.
Click import curve.
5.
In the curve: field, enter stress_strain_curve.
6.
In the sigy = field, enter 185 (MPa).
7.
In the k = field, enter 550 (MPa).
8.
9.
Click create.
10. Click back.

11. Click create.
12. Click on add to database. A folder browser is displayed, allowing you to browse for a folder into which
the newly created material file will be saved. This will be a one time operation for every new material
created, after which you can access the material using the Material Database option in the Setup
menu.

14. Click return to exit out of the Materials panel.

1.
From the Setup menu, click Components.
2.
Click component: and select blank.
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3.
4.
5.
Select the adaptive check box.
6.
Click update.
7.
Click return.
Step 7: Autoposition the blank onto tools

1.
From the Tools menu, click Auto Position.
2.
Select the autoposition subpanel.
3.
Select the multipart radio button.
4.
Click punch: comps twice and select the Punch component.
5.
Click binder: comps twice and select the Binder component.
6.
Click die: comps twice and select the Die component.
7.
Click blank: comps twice and select the Blank component.
8.
Click the moving part toggle to die.

Note: This tutorial contains a single action draw problem. In single action draw, the punch remains
stationary and the die closes in the z direction. Therefore, the moving tool is set to the die and
the direction is set to Z axis -.
9.
Click adjust. This operation takes few seconds depending on the complexity of the setup.
10. Click return.
Tools and blank after autopositioning
Step 8: Define the tool motion

1.
From the Setup menu, click Tool Motion. The Tool Motion panel is displayed.
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2.
Click moving tool and select the die component.
3.
Click max velocity and enter 5000 (mm/s).
4.
Click total travel and enter 38.0 (mm).
5.
Click set up.

Note:
After auto-position, the distance between die and punch is about 36.0 mm. Final distance
between punch and die = = 39.2 approximate blank thickness * 1.2 = 39.2 (1.0 * 1.2) = 38.0
mm.
The blank section property defined in step 4 will be overwritten by the actual thickness carried
from previous forming result within the STA/DYNAIN file. The STA/DYNAIN file contains nodal
thickness results.
6.
Click return.

1.
From the Setup menu, select Tool Load.
2.
3.
Click tool force and enter 200000. (N)
4.
For Incremental_Dyna only: Click max velocity and enter 5500 (mm/s). keep all the other default
options.
5. Click set up.

You apply a force of 200kN to the binder. A rigid body stopper limits the maximum velocity of the binder
in order to minimize inertial effects. The maximum velocity is 10% greater than the punch velocity,
allowing the blankholder to adjust for thickening or wrinkling of the blank.
6.
Click return.
Step 10: Setup contacts between the blank and the tools
1.
From the Setup menu, click on Contacts.
2.
Click on the multiple subpanel.
3.
Next to master: field, click on comps and select Binder, Die and Punch.
4.
Next to slave: field, click on comps twice and select Blank.
5.
Click create.
6.
Click return.
Step 11: Modify the adaptivity settings

These steps should be followed for Dyna only:
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1.
From the main menu area, click control cards.
2.
Click the Adaptive control card.
3.
Click ADPSIZE and enter 11.2 (mm).
4.
Click return.
5.
Click return.
ADPSIZE defines the minimum element size to be adapted. To maintain the adaptive levels in the blank,
this parameter should be set to an element size which is slightly less than twice the size of the smallest
element in your adapted blank (ADPSIZE = 1.95*smallest characteristic length). During each adaptive
cycle, LS-DYNA checks to see if any elements have a characteristic length greater than ADPSIZE, if so,
then those elements can potentially adapt. Conversely, the elements smaller than ADPSIZE are not
allowed to adapt.
For this example, the smallest characteristic length in the blank after 3 levels is
ADPSIZE = 5.76*1.95 = 11.2 mm.
5.76 mm so the
Step 12: Update the contact with die motion

1.
2.
Right click on Die_to_blank and select Card Edit.
3.
Scroll to the bottom of the sections as shown in red box in the image below:
4.
Click on the Number of Load Collectors toggle and select 2.

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5.
Click on the button loadcollector_ids(2) and select loadcol_IMP-die.
6.
Click return.

1.
In the Model Browser, right click on Binder_to_blank and select Card Edit.
2.
3.
4.
Click on the button loadcollector_ids(2) and select loadcol_CLOAD-binder.
5.
Click return.
Step 14: Save the analysis

1.
2.
Save the file as redraw_radioss_complete.hf or redraw_complete.hf
3.
Click save.

1.
2.
Click animation.
Note: Notice the kinematics of the tool motion. This animation feature enables you to review and correct
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the tool motion.

3.
Click run to start the computation in RADIOSS.
1.
From the Utility Menu, under Setup, click the Run button. This brings up the incremental analysis
panel.
2.
Make sure that the path to the LS-DYNA executable is set. To do this, edit the lsdyna.bat file in the
<installation_directory>/hm/scripts/hyperform/automation/ directory.
3.
Click return.
4.
Click run.
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In this tutorial, you will learn about the Multiple Stage Manager. The Multiple Stage Manager provides a
convenient graphical setup for modeling forming processes that are composed of multiple stages. It provides
a dialog to assemble multi-stage processes by clicking icons that correspond to each step.
The Multiple Stage Manager supports several types of forming process stages in incremental analysis
such as gravity, forming, drawing and trimming. It can calculate many of the input values required for an
incremental forming run while still allowing overrides for user-defined data.
Complete the tutorial HF-3001: Auto Process prior to beginning this tutorial.
This tutorial assumes that you are familiar with basic functionality such as geometry cleanup, meshing, and
mesh editing. If you need help on these topics, please refer to the corresponding tutorials in the on-line help.
Tools
The Multi-stage Manager is available in the Tools menu, under Multiple Stage Manager when the
Incremental_Radioss or Incremental_Dyna user profile is loaded.
Exercise: Use Multiple Stage Manager to set up multiple

forming analysis stages
In this exercise, you will set up a multiple-stage forming analysis using gravity, double-action draw and
trimming operations.
For Radioss:
multistage_gravity_radioss.hf
multistage_double_action_draw_radioss.hf
multistage_trim_line.hf.
For Dyna:
multistage_gravity.hf
multistage_double_action_draw.hf
multistage_trim_line.hf.
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1.
Click on
<installation_directory>\tutorials\mfs\hf\incremental\multistage_gravity_ra
dioss.hf.
2.
Click Open.
Step 2: Review the Multiple Stage Manager interface

1.
From the Tools menu, select Multi Stage Manager The Multi Stage Manager dialog opens, as
shown below.
Project name: The user-defined name of the project.

Location: A working directory for all the associated model files.
Stages: A variety of forming analysis types is available. To apply a forming stage, select a stage by
double-clicking its icon and that stage is appended to the sequence list on the right side of the dialog
(current active forming sequence in the image).
Sequence: The selected forming sequence that will be simulated. You can right-click an active forming
sequence and select delete to remove the process from the active sequence window.
Process build/setup tool: From the Process menu, click Setup to access the parameters for the
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currently-selected process stage. Two tabs, Setup and Details, appear in the left side of the dialog on
which you can specify all the details of the analysis and review the settings.
File: Create, open and save a new project.
You can simulate complex, multi-stage processes in the Multi Stage Manager by following four simple
steps listed below:
Select process stages to add them to the process sequence
Specify a source file for each stage
Specify setup parameters for each stage
Run the process
Step 3: Build the forming sequence

1.
For the Project name field, input New_process (default).
2.
Click on the button

next to the Location field, and browse for a target location folder to save the
process file and model file.
3.
Under Stages, double-click the picture with the name Gravity.
4.
Notice the Gravity icon appears under Sequence. This indicates a gravity forming analysis is the first
incremental forming analysis in the entire project.
5.
Click on the Gravity icon. Notice a red line is surrounding the icon indicating that the gravity sequence is
currently selected.
6.
Click on
in front of the Source file field and browse to locate the file
<installation_directory>\tutorials\mfs\hf\incremental\multistage_gravity_ra
dioss.hf for Radioss and
<installation_directory>\tutorials\mfs\hf\incremental\multistage_gravity.
hf for Dyna.
7.
Click Open. The selected .hf file is assigned to the gravity process as a source file.
8.
Double-click Double Action Draw. Notice the Double Action Draw icon appears under the Sequence
list.
9.
Repeat steps 5 and 6 to assign multistage_double_action_draw_radioss.hf for Radioss and

multistage_double_action_draw.hf for Dyna to the Double Action Draw.
10. Repeat the above steps to make Trim active in the Sequence list and assign the
multistage_trim_line.hf file.
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Step 4: Set up the Gravity process

1.
Under Sequence, click the Gravity icon.
2.
Click on the Process tab at the top of the window and select Setup. This brings up the process setup for
gravity analysis.
3.
For Symmetry/Constraints:, select No.
4.
For Draw direction:, select z.

For Dyna, select Implicit as the Gravity option.
5.
Under the Name column, click on the space left to Blank1. Notice an arrow (
6.
With blank1 selected, under the Source column select HF.
7.
With blank1 selected, under the Component column, verify Blank is selected.
8.
With blank1 selected, under Material, click the open folder icon
Materials window.
240
) appears.
and select CRDQ steel from the

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Radioss material database
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241
Dyna material database
9.
Click Select to accept the material.
10. With blank1 selected, under Thickness column, enter 1.0.

11. Click on the space left to Tooling. Notice an arrow (
) appears next to Tooling.
12. With Tooling selected, verify HF under Source and select Die under Component.
Notice the pink die component color is shown as a solid line in the Multiple Stage Manager image.
Step 5: Set up the double action draw process
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1.
Under Sequence, click the Double Action Draw icon. Notice that the source file for Double Action
Draw displays in the graphics area.
2.
For Draw beads, select No.
3.
For Symmetry/Constraints select No.
4.
For Draw direction, select z.
5.
For Motion type, select Velocity.
6.
For Blank1, verify the name under Source is set to State file.
Note:
At the end of the first stage gravity analysis, a STA file for Radioss and a Dynain file for Dyna is
generated and imported into second stage double action draw forming as the initial blank. This
file contains the shape of the blank in additional to the stress and strain output after the gravity
stage.
7.
Verify that the remaining Source column values are set to HF.
8.
For Die, Punch and Binder names, verify Component column is set to Die, Punch and Binder
respectively.
9.
For Punch, click on Clearance and enter 0.0.

The meaning of different motion controls for the tools is enumerated below
Clearance: This is the value for the distance between the punch and the blank at the initial stage. When
clearance value is assigned, the Travel1 and Travel2 values will be adjusted accordingly.
Travel 1: The distance the punch travels towards the blank until the binder is closed.
Velocity 1: The velocity at which the punch travels towards the blank. The suggested velocity is 2000
mm/s
Travel 2: The distance the punch travels towards the die after Travel 1 until the end of the draw.
Velocity 2: The velocity at which the punch travels for Travel 2. The suggested velocity is 10000 mm/s
Note:
Travel1 + Travel2 distance is the total travel of the punch. If you wish to specify values for
Travel 1 and Travel 2, you need to turn off autopositioning in the settings.dat file.
10. Click on Binder and change the Type to Gap. Enter the values as shown below:
Gap: 0.0 (default)
The meaning of different motion controls for the tools is enumerated below
Travel: type a value for the distance the binder travels toward the die.
Velocity: type a value for the velocity at which the binder travels toward the die. The suggested velocity
is 2000 mm/s.
Type: select Gap or Force for the binder. If you choose Force, type a value (in Newtons) in the Force
column that appears to the right. If you choose Gap, type a value in the Gap column that appears to the
right. Gap is defined as the actual physical distance between the binder and die that is maintained after
the binder closure until the draw is completed, minus the blank thickness + 20% of blank thickness.
Note:
When gap value is specified, travel distance is automatically calculated and assigned. If you wish
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to specify values for Travel, you need to turn off autopositioning in the settings.dat file.
Step 6: Set up the trimming process

1.
Under Sequence, click on Trim.
2.
Under the Name column, click on the space left to Trim. Notice an arrow (
3.
With Trim selected, under Component column, select line.
4.
With Trim selected, under Remove column, verify Outside is selected.
) appears.
Step 7: Save the process and run the analysis

1.
Within the Multiple Stage Manager, from the Files menu, select Save Process. Notice a message
appears at the bottom of the Multiple Stage Manager window showing the path of the saved process
file.
2.
From the Process pull-down menu, select Run.

The Radioss solver is launched.
To make the solver launch automatically as outlined about for Radioss, complete the following.
HyperForm incremental forming analysis uses LS-DYNA as the solver. In order for HyperForm to launch the
solver directly, you must specify the solver environment by performing the following steps:
1.
Open <HyperWorks installation>\hm\scripts\hyperform\automation\lsdyna.bat

using any text editor.
2.
Remove any lines above "REM Remove the lines above and point the line below to lsdyna-executable".
3.
Point to the full path and LS-DYNA executable.

Example: C:\LSDYNA\program\ls970_s_5434a_win32.exe i=%1
4.
Save and overwrite the lsdyna.bat file.
Step 8: (optional): Review result files

1.
Upon completion of the Radioss/Dyna run, review the result files in the following directories.
stage_1: contains the input deck and result files for Gravity run
stage_2: contains the input deck and result files for Double draw action run
Stage_3: contains the input deck and result files for Trim run.
Note: The input deck is the <filename>_0000.rad and <filename>_0001.rad files. The input deck for Dyna
is the key file.
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2.
Review the Animation files within each folder using HyperView.
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In this tutorial, you will learn the tube bending setup procedure using a simple tube bending process.
This tutorial assumes that you are familiar with basic bending process parameters.
Tools
This utility can be accessed from the Tools menu under the Bend option, as shown below:
The following panels used in this tutorial can be accessed from the Setup menu:
Materials panel
Components panel
Run analysis panel
Exercise: Basic Tube Bending Analysis

This exercise creates the model file and sets up a tube bending simulation from scratch. Standard tooling
geometries can be created from HyperForm and no preliminary file needs to be loaded to perform this tutorial.
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Step 1: Create the tube bending model

1.
From the Tools menu, select Bend and then select Model Creator. The following panel is displayed.
2.
Enter the values shown in the fields below:
Field Description
Values
Tooling Parameters
Form Tool Center X
0.0
Form Tool Center Y
0.0
Form Tool Center Z
0.0
Bend Die Radius (mm)
163
Offset From Center (mm)
100
Ball Parameters
Number of Balls
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Ball Outer Dia (mm)
70.3
Tube Parameters
3.
Outer Dia (mm)
76.2
Tube Length (mm)
750
Wall Thickness (mm)
2.6
Length Before First Bend (mm)
156.6
Click Apply.
The graphical definition of all parameters is illustrated in the image below.
Note : Outer Dia = Tube diameter ( at mid surface of a tube) + Wall Thickness.
Step 2: Create the tube material properties

1.
From the Setup menu, select Materials.
2.
3.
Click card image:, and select the respective card image from the list.
Note:
For Radioss, select HillOrthotropic Tabulated as the card image

For Dyna, select TransAnsioElasticPlastic as the card image
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4.
Click import curve.
5.
6.
7.
8.
9.
Click create.
10. Click back.

11. Click create.
12. Click return.
Step 3: Assign material properties for the tube component

1.
From the Setup menu, select Components.
2.
Double-click component: and select Tube.

Note that the section: field is already updated with Tube.
3.
4.
Verify that the adaptive check box is not selected.
5.
Click update.
6.
Click return.
Step 4: Set up the bending simulation

For the Incremental_Radioss User Profile:
1.
From the Tools menu, select Bend and then select Bend Setup. Type the file name as
tube_bending and specify the required location to save the file.
2.
After saving, the bend setup utility appears:
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Notice that some component selections are already done.

3.
Set the Number of Bends field to 3 to specify the number of bends.
4.
Enter the following in the table to provide the bend sequence data:
5.
Translate
Rotate
Bend Angle
156.2
56.2
87.2
-49.2
50.2
99.7
126.1
29.8
Click Run. The folder where you saved the file will have <filename>_0000.rad and
<filename>_0001.rad installed. The number of <filename>_000* files depends on the number of
bends in the Bending setup. In this case, it is 6 files 0001.rad, 0002.rad, 0003.rad, 0004.rad,
0005.rad and 0006.rad files.
The tube bending problem has been set up completely.
Note:
All tool parameters from the Bending Model Creator dialog are automatically applied to the
"Bending Setup". However, if you create the tube and tool meshes without using the Bending
Model Creator dialog, you will need to manually modify [install_directory]
\scripts\hyperform\hydroforming\TubeBendingInitDefaults.dat to suit your
needs.
For Incremental_Dyna user profile:

1.
Under Setup, click Bending Setup. The following dialog appears:
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2.
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Make the following component selections in the Hydro Tube Bending dialog by using the selector for
the corresponding fields.

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3.
4.
Selector label
Component to Select
Form die:
FormDie
Mandrel:
Mandrel
Wiper die:
WiperDie
Pressure die:
PressureDie
Tube:
Tube
Tube rigid control:
CntrlRigid
Number of forming balls
Ball number 1:
ball_1
Ball number 2:
ball_2
Number of bends
Enter the following in the table for bend sequence data:
Translate
Rotate
Bend Angle
156.2
56.2
87.2
-49.2
50.2
99.7
126.1
29.8
Click Run.
The tube bending problem has been set up completely.
Note:
All tool parameters from the Bending Model Creator dialog are automatically applied to the
"Bending Setup". However, if you create the tube and tool meshes without using the Bending
Model Creator dialog, you will need to manually modify [install_directory]
\scripts\hyperform\hydroforming\TubeBendingInitDefaults.dat to suit your
needs.
Step 5: Save the analysis setup as tube_bending_complete.hf

1.
From the File menu, select Save As.
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2.
Use the file browser to save the file as tube_bending_complete.hf.
3.
Click save.

1.
Run the analysis from the Radioss Manager. The Radioss Manager can be accessed from Start - All
Programs - Altair HyperWorks 11.0.
Note: Do not use the Run function from the Utility Menu or the main panel area. This will rewrite the
D00 and D0* files created from the Bending setup.
2.
Click run. An LS-DYNA input file named forming_complete.bdf is generated. The file can be
submitted to LS-DYNA for solver analysis (in the Incremental_LsDyna user profile).
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Hydroforming is a metal forming process that involves using fluid pressure to shape the metal piece. It begins
with the metal piece to be formed being placed in a blank holder over the punch. The blank holder and punch
are then moved next to the fluid filled dome. Pressure inside the dome is increased to form the part. As the
punch moves against the diaphragm of the dome, the pressure inside the dome is adjusted to form the part
to the desired shape.
In this tutorial, you will learn how to set up of a tube hydroforming process.
This tutorial assumes that you are familiar with basic HyperForm functionality such as meshing and mesh
editing. If you need help on these topics, refer to the corresponding tutorials in the online help.
Tools
This tutorial uses the following panels which are available in Setup menu:
Sections panel
Materials panel
Components panel
Run Analysis panel
Exercise: Basic Tube Hydroforming Analysis

tube_radioss.sta
hydro_die_geom_radioss.igs
tube_dynain
hydro_die_geom.igs
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Radioss Setup model
Dyna Setup model
Step 1: Import a STATE/DYNAIN file

1.
Copy the file tube_radioss.sta from it's location in the installation directory at
\tutorials\mfs\hf\incremental to the location where you intend to run this simulation after
setup.
2.

. The Import tab opens with the options as shown below. Make sure that the
selection is per the figure:
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3.
Click the file browser icon
4.
Click Open...
5.
Click Import.
Note:
and browse to find the file tube_radioss.sta or tube_dynain.
During import of the sta/dynain file, only the node and element definitions are read into HyperForm.
The adaptive constraints, initial stress, and initial strain quantities are automatically placed into a
new file called filename.sta.hmx/dynain.hmx. This extra information should be
automatically included in the new setup by use of the #INCLUDE in the D00 0000.rad file for
Radioss and *INCLUDE card for Dyna.
Step 2: Rename the STA/DYNAIN component

1.
2.
Right-click on the component 1 and select Rename.
3.
Enter the new name as Tube and click Enter.

1.
From the Setup menu, click Sections.

The Section Definition panel is displayed.
2.
In the section: field, type tube_section.
3.
In the thickness: field, type 1.3(mm).
4.
Click card image: and select the respective card image from the list:
For Radioss, select SH_ORTH
For Dyna, select SectShll
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5.
Click create.
6.
Click return.
Step 4: Create tube material properties

1.
From the Setup menu, click Materials.

The Material definition panel displays.
2.
3.
For Dyna, select TransAnsioElasticPlastic
4.
Click import curve.
5.
6.
7.
8.
9.
Click create.
10. Click back.

11. Click create.
For Dyna, click edit card and set Lankford coefficient (R) to 1.6.
12. Click return.
Step 5: Assign section and material properties for the tube component
1.
From the Setup menu, click Components.
2.
Double-click component: and select Tube.
3.
Click section: and select tube_section.
4.
5.
Select a color.
6.
Select the adaptive check box.
7.
Click update.
8.
Click return.
Note:
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By default, three levels of adaptivity are enabled. The adaptive levels can be changed by using the

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Control Card panel, and editing the parameter LevelMax in the card /ADMESH/GLOBAL for
Radioss and the parameter MAXLVL in the Adaptive card for Dyna. Refer to the RADIOSS/LSDYNA manual for more detailed information.
Step 6: Import the die geometry

1.
2.
Click on the Import Geometry icon
3.

and browse to find the file hydro_die_geom_radioss.igs/
hydro_die_geom.igs and double click to open the file.
4.
Click Import.
5.
Click Close.
. The Import tab opens.

to change to geometry import options.
Step 7: Rename the upper and lower die components

1.
2.
Right-click on the component lvl3 and select Rename.
3.
Enter the new name as upper_die and click Enter.
4.
Right-click on the component lvl4 and select Rename.
5.
Enter the new name as lower_die and click Enter.
Step 8: Display only the upper and lower die components

1.
In the Model Browser, click the surface icon as shown in the figure below to turn on lower_die and
upper_die components.
Step 9: Set the current component to Upper_Die

1.
In the Model Browser, under the Components folder, right click on Upper Die and select Make
Current as shown below.
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Note: This sets the current working component to be upper_die.
Step 10: Mesh the Upper_Die component using R-mesh

R-Mesh is a tool meshing utility available from the Mesh menu that allows you to specify several parameters
to create the mesh. The macro is intended for generating rigid tool meshes for incremental analysis. For
incremental analysis, the meshing parameters default settings are Minimum Edge: 0.5, Maximum edge:
30.0, Chordal deviation: 0.1, and Fillet angle: 15.0.
The four parameters are defined as shown in the interface as shown below.
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1.
From the Mesh menu, click R-Mesh.

The default parameters can be used here.
2.
Select the Mesh to current component check box.
3.
Click Mesh
4.
Select the yellow surfs button and select by collector.
5.
Select the upper_die component and click proceed.
6.
Click Close.
Step 11: Repeat Steps 9 and 10 using lower_die as the current component
1.
Set the lower_die component as the default working component.
2.
Mesh the lower_die surface using R-Mesh.
Step 12: Set up pressure loads using the Hydro Setup macro
1.
Click Tools > Hydro > Hydro Setup.
2.
A window pops up asking you to save the file. Type the file name as
tube_hydro_radioss_complete and specify the required location to save this file.. The
HydroForming utility displays as below
3.
For Upper Die:, choose the upper_die component.
4.
Click Velocity: and type -2000. (mm/s)
5.
Click Total travel: and type 8. (mm)
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6.
For Lower Die:, select the lower_die component.
7.
For Tube:, select the Tube component.
8.
For Adaptive levels:, change from the default of 3 to 1.
9.
Click Coeff of friction: and type 0.125.
10. Click Initial pressure: and type 1000. (psi)

11. Click Final pressure: and type 6000. (psi)
12. Click Run to set up the hydroforming pressure loads.
Notice the pressure curve and velocity curve are set on screen.
Note:
For Radioss, D00 and D01 files are created at this step. Save the file as in Step 13 and directly
use the Radioss Manager to run these files. The Radioss Manager can be accessed from
Start - All Programs - Altair HyperWorks 11.0.
Do not execute the Run command either from the Utility Menu or the main panel area.
Step 13: Save the analysis setup

1.
Click File > Save As....
2.
Enter the file name as tube_hydro_complete.hf.
3.
Click Save.
Step 14: (Incremental_Dyna Only) Review the animation and run the analysis
1.
Under Setup, click Run.
2.
3.
Click applied comps: comps and select Tube.
4.
Click select.
5.
6.
Click setup.
A message appears stating: "The entity set has been created."
Note
At the end of the computation, LS-DYNA will write out a file named "dynain". This file contains
all the stress and strain information necessary to perform subsequent operations. This file can
be read directly by HyperForm and is essential for performing multi-stage setups.
7.
Click return.
8.
Click dyna file and specify the name tube_hydro_complete.
9.
Click run. A dyna input file tube_hydro_complete.bdf is generated. The file can be submitted to
LS-DYNA for solver analysis.
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In order to precisely capture the final part profile after performing an incremental forming analysis, the
deviation between the final part edge from the analysis and the targeted part edge is measured and applied to
original blank profile. A new blank shape is then generated based on the applied deviation. Material is
removed or added in areas corresponding to deviations of the part edge with respect to the target edge. This
process is called blank optimization and will be studied in this tutorial.
Tools
This tutorial uses functionality available in the Tools menu, with the Blank Opti option.
Exercise 1: Blank Optimizer without web exclusions

This exercise uses the model files:
Incremental_Radioss:
BlankOptiFinal.STA
BlankOptiInitial.nas
BlankOptimize_TargetLine_Radioss.iges
Incremental_Dyna:
final-dynain
initial_dynain
BlankOptimize_TargetLine.iges
You do not have to load these files individually. When you start the Blank Optimizer, you need to indicate
your root directory. This root directory should contain the files mentioned above. The function will load the
appropriate model at the appropriate time in the task.
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Step 1: Open the file and select the root directory

The model files are zipped in the tutorial location. Before proceeding, unzip the files and copy the files into a
convenient working folder. This will be used as your root directory.
1.
From the Tools menu, select Blank Opti and then choose Select Root Directory.
A dialog box pops up with the instructions about file format and their locations, as shown below.
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Incremental_Dyna dialog
2.
Click on Proceed.
A dialogue box pops up asking you to change the exiting location of the root directory You need to point
to the directory where the model files are stored. Please note that there cannot be any spaces in the root
directory path.
3.
Click on Yes to change the directory, or No to accept the default directory. If Yes, browse the appropriate
directory and click OK.
Step 2: Optimize the initial blank

1.
From the Tools menu, select Blank Opti and then choose Blank Opti Setup.
The utility makes a comparison between the boundary of formed part and the target boundary to
calculate the deviation. This deviation is applied to the initial blank and a new boundary for the blank is
created as shown below.
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The zoomed area shows the deviation applied to the flat blank
Exercise 2: Blank Optimizer with Web Exclusions

This process is typically used to optimize the blank shape for progressive die forming where the blank shape
for optimization is considered excluding the webs connecting the continuous strip of blanks.
This exercise uses the model files:
Incremental_Radioss:
BlankOptiFinal.STA
BlankOptiInitial.nas
BlankOptimize_TargetLine_WebExclusion_Radioss.iges
Incremental_Dyna:
final-dynain
initial_dynain
BlankOptimize_TargetLine_WebExclusion.iges
Step 1: Optimize the initial blank

Before beginning, copy the files to a convenient working folder. This will be your new root directory.
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Note: Radioss and Dyna files should be kept in separate working folders.
1.
From the Tools menu, select Blank Opti and then choose Select Root Directory.
2.
Click on Proceed.
A dialog box pops up asking you to change the exiting location of the root directory You need to point to
the directory where the model files are stored. Please note that there cannot be any spaces in the root
directory path.
3.
Click on Yes to change the directory, or No to accept the default directory. If Yes, browse the appropriate
directory and click OK.
Step 2: Exclude web elements from the initial blank

1.
From the Tools menu, click Blank Opti and then Select Web Elements.
The flat blank will load into the session with the web selection options
2.
In the Enter no.of webs field, type 1.
3.
Click on proceed.
4.
Click on elements and select approximately half of the elements, as shown in the figure below.
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Incremental Radioss selection
Incremental LsDyna selection
5.
Click on proceed.
6.
From the Tools menu, click Blank Opti and select Blank Opti Setup.
7.
In the file selection dialog, select BlankOptimize_TargetLine_WebExclusion_Radioss.iges

for Radioss, and BlankOptimize_TargetLine_WebExclusion.iges for LsDyna.
8.
Click Open.
This will apply the deviation to on half of the blank as opposed to full blank. Deviation compensated blank
is shown below:
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Die Module
The following Die Module tutorials are available:

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Die Process is a browser based approach for creating and editing addendum and eventually the die cavity.
The addendum is a part of the die face and that facilitates the smooth and controlled flow of the metal into
the die cavity. HyperForm allows you to create the addendum and construct a complete die with the part
profile as the input. First a binder is constructed and the addendum is built connecting the part and the
binder surface. The binder is then trimmed to get a complete die cavity. The addendum can also be created
with different cross sections depending on the complexity of the part shape. You also have the flexibility of
modifying the cross section of the addendum depending on the changes to the part design.
Exercise: Designing an Addendum with a Constant S-Section

1.
From the File menu, click Open....
2.
Browse to the file <installation_directory>\tutorials\mfs\hf\die\cup_addendum.hf.
3.
Click Open.
Step 2: Import the draw bead line

1.
Click on the Import icon
2.
Select the Import Geometry icon
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275
3.

to select the file to import. From the installation directory used above,
select the file drawbead.iges.
4.
Click Open.
5.
Close the Import tab.
Step 3: Establish the Die Process settings

1.
On the Die Process tab, under the Settings heading, right-click on Symmetry and select Edit, as
shown below. This opens the Symmetry Setting panel.
2.
Make sure the toggle is set to full.
3.
Click return.
4.
In the Die Process tab, under Settings, right-click on Stamping Direction and select Edit. The
Stamping Direction Settings panel opens.
5.
Ensure the direction is set to Z-axis.
6.
Click Set.
Step 4: Establish the Die parameters

1.
Under Die, right-click on Part: (none) and select Set....
2.
Select the part from the graphics screen and click proceed.
Note that the name of the component appears in front of the label Part:. For this example, Part: Part
appears.
3.
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Step 5: Create a trim line

1.
Under Die, right-click on TL and select Create > From Part.
The trim line (a line representing the part boundary) will be created in a temporary collector called TL.
Step 6: Create the binder

1.
Under Die, right-click on Binder and select Create > From Part.
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The binder is created in a temporary collector called Binder.
Step 7: Create the addendum

1.
Under Die, right-click on Addendum and select Create > From Part.
The addendum is created in a temporary collector called Addendum.
Step 8: Create the draw bead on the die face

1.
Using the Model Browser, make sure that the display of drawbead.iges is turned on.
2.
In the Die Process tab, right-click on Drawbeads (optional) and select Create.
3.
Enter 6 in both the Radius and Fillet fields.
4.
Click create.
5.
Pick the binder surface from the screen and click proceed.
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6.
Select the line representing the drawbead on the binder (die face) and click proceed.
7.
Select one node above or below the binder.
8.
Click proceed.
The drawbead is created along the line with the specified dimensions.
Step 9: Create the die cavity and mesh

1.
Right-click on the white space in the Die Process tab and select Trim Binder > With Addendum, as
shown below.
2.
From the menu bar, click View > Toolbars > Display. Click on the Display Fixed Point icon
turn off the display of the fixed point from the die.
3.
In the Model Browser, turn off the geometry display for all of the components to display a clear view of
the meshed cavity die.
to
Step 10: Create the punch and binder

1.
In the Die Process tab, right click on Punch: (None) and select By Offsetting Part and Addendum.
2.
Enter a value for the offset. The offset distance will be the gap between the punch and the die, which
should be equal to blank thickness+20% of blank thickness.
3.
Click on Offset+ or Offset- based on the direction of the vector.
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4.
Click Return.
The punch will be created in a collector named Punch. The object punch in the die process tree reflects the
name of the punch component.
5.
Right click on Blank Holder: (None) and select By Offsetting Binder.
6.
Enter a value for the offset. The offset distance will be the gap between the punch and the die, which
should be equal to blank thickness+20% of blank thickness.
7.
Click on Offset+ or Offset- based on the direction of the vector.
8.
Click return.
The binder will be created in a collector named Binder. The object binder in the die process tree reflects the
name of the binder component.
It is advised to keep the blank ready by using tools in the Radioss One Step profile prior to creating tools.
You can also switch to the Radioss-Incremental user profile and use the functions Auto Process and/or User
Process to setup the solver parameters for Radioss Incremental.
Punch and binder w ith the die
9.
Create a new component called Die Cavity and organize the elements of the binder, addendum, and
part.
This tutorial is now complete.
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The addendum is a part of the die face and that facilitates the smooth and controlled flow of the metal into
the die cavity. HyperForm allows you to create the addendum and construct a complete die with the part
profile as the input. First a binder is constructed and the addendum is built connecting the part and the
binder surface. The binder is then trimmed to get a complete die cavity. The addendum can also be created
with different cross sections depending on the complexity of the part shape. You also have the flexibility of
modifying the cross section of the addendum depending on the changes to the part design.
This tutorial assumes that you are familiar with basic HyperMesh functionalities such as creating
components, geometry cleanup, and meshing. Information on these topics can be found in the online help.
Tools
This tutorial uses the following macros:
From Elements macro under Create Trim Line
Flat macro under Create Binder
Edit Binder macro under Create Binder
Constant S macro under Create Addendum
Components macro under Setup of 1Step macro menu
Exercise: Designing an Addendum with a Constant-S Section

1.
From the File menu, click Open....
2.
Browse to the file <installation_directory>\tutorials\mfs\hf\die\cup_addendum.hf.
3.
Click Open.
Step 2: Create a trim line for the part
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1.
Click Geometry > Line Design.
2.
In the part boundary subpanel, click elems >> displayed.
3.
Click create.
Notice the message "Trim line is created" on the header bar. This creates a feature line forming the
outline of the part that is stored in the ^feature component. This line will be used later as the trim line.
4.
Click return.
Step 3: Create a binder component and assign a material to it

1.
Click Applications > Radioss One Step. This opens the Radioss One Step user profile within
HyperForm.
2.
Click Setup > Components. This opens the Components panel.
3.
Input Binder in the text field for Component:.
4.
Click on the materials button and select CRDQ Steel.
5.
Click on the color button and assign a color to the binder component.
6.
Click create.
7.
Click return.
Step 4: Create a flat binder

1.
Click Applications > Die Module. This brings you to the Die Module user profile.
2.
From the Geometry menu, click Binder. Select the flat subpanel.
3.
Input offset = 20.0 and set the toggle to full model.
4.
From the tool bar, select the
5.
With the nodes button highlighted, from the graphics area, click on the empty region below the model.
icon.
Notice a temp node is created.
6.
Click create. A flat binder is created on screen.
7.
Click return.
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Step 5: Translate a flat binder

1.
From the tool bar, select the top view

on the binder surface.
2.
From the Utility Menu, under Create Binder click on the Edit Binder panel.
3.
Select the Translate subpanel.
4.
Make sure that the selector is set to binder.
5.
Switch the direction from N1, N2, N3 to Z-axis.
6.
Press keyboard F4 (the function key 4) to enter the Distance panel.
7.
With N1 highlighted, click and hold down the left mouse button and move the mouse cursor on an edge
of the binder to highlight a line. Once the binder edge is highlighted, click on the line again to create a
temp node.
8.
Repeat the procedure for N2, but click on any node on the part edge.
icon Notice that the original part is approximately centered
Notice the distance between N1 and N2 is measured and displayed. Refer to the image below:
9.
Note the value of z dist = . The distance in Z direction will be used later.
10. Click return. You are back to the Edit Binder panel.
11. With the noted value from the Distance panel, arrive at a value so that the distance is equal to 20mm
between the binder surface and the top of the part. Enter that value in the Magnitude = field.
(For example, if the previous value is 10.0, you will have to translate binder in negative Z direction by 10.0
to be able to achieve a distance = 20.0 between the binder and the part.)
12. Click on Translate+ or Translate- accordingly.
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Picture show ing the binder and the part
Step 6: Build the addendum

1.
Click Applications > Radioss One Step.
2.
Under Setup, click Components.
3.
Input Addendum right next to component:.
4.
Click on material: and select CRDQ Steel.
5.
6.
Click create.
7.
Click Applications > Die Module.
8.
From the Geometry menu, click Addendum, and select the Constant S-section subpanel.
9.
Click the line button next to TL:. With the line button highlighted, pick the trim line created in step 2
from the graphics screen (stored in the ^feature component). Once the line is picked, it highlights in
white color and the surf button next to Binder: is highlighted in the panel area.
10. With the surf button highlighted, click on the binder surface from the graphics screen.
11. Click on the purple parameters button.
This takes you to the control parameters for addendum creation.
Plus length: A straight line section added to the outer edge of a part (10 mm default).
Wall angle: Section wall angle (15 degrees default).
Entry radius: Die entry radius (10 mm default).
Constrain plus to part: Plus length will be constrained so that it is tangent with respect to the edge of
the part. (ON by default).
Enable fixed points: Fixed points will be placed along the edge of the new addendum surface if a finite
element mesh exists. If the nodes lie along the edge and are within a tolerance, a fixed point will be
generated. (ON by default).
Split into small faces: Generated surfaces are divided into smaller areas in order to simplify their
definition while reading and manipulating them in other CAD systems. (ON by default).
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12. Enter plus length = 3.0, wall angle = 5.0 and entry radius = 3.0.
13. Click return.
14. Click on the create addendum button.
This creates an addendum forming a smooth connection between the part and the binder surface.
15. Click return.
Step 7: Edit the model to arrive at the final die cavity

1.
From the Preferences menu, click on Meshing Options. Select the graphics subpanel and uncheck
the fixed points option. Click return to close the panel.
2.
Click Geometry > Edit > Surfaces > Trim with lines.
3.
From the toolbar, select the
4.
Highlight the surfs button under with lines and pick the binder surface from the graphic screen.
5.
Click on the yellow lines button below the surfs button. From the graphics screen, click and hold down
the left mouse button and move the mouse cursor to highlight the entire surface edge of the created
addendum. Refer to the image below:
top icon.
Highlight the entire surface edge of the addendum
6.
Click on the first toggle below the lines button to make the option as normal to surface.
7.
Verify the lower toggle is set to entire surface.
8.
Click on the trim button. This will trim the binder covering the die cavity.
9.
Click on return.
10. From the toolbar menu, select the bottom
icon.
11. Press F2 on the keyboard. This will take you to the Delete panel.
12. Set the yellow entity selector to surfs.
13. Click at the center of the binder to highlight the portion of the binder (which was trimmed out in steps 6
through 10) covering the die cavity.
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14. Click on the delete entity button. This will give the final die cavity with the addendum and the die face.
Pictures show ing the final die w ith the addendum.

1.
2.
Enter the file name as cup_complete.hf.
3.
Click Save.
Return to Die Module Tutorials
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The addendum is a part of the die face that facilitates the smooth and controlled flow of the sheet metal into
the die cavity. HyperForm enables you to rapidly create a parametric addendum and construct a complete
die with the part profile as the input. First a developable binder is constructed and then the addendum is built
connecting the part and the binder surface. The binder is finally trimmed to get a complete die face. An
addendum can be created with single or multiple cross-sections depending on the complexity of the part
shape. You also have the flexibility of parametrically modifying the cross-sections of the addendum in order
to create different die geometries.
Three exercises are contained in this tutorial:
Exercise 1: Geometry cleanup for creating an addendum
Exercise 2: Building an addendum for a flat binder
Exercise 3: Building an addendum for a curved binder using Rib Editor
Tools
This tutorial uses the following features:
From Elements macro under Create Trim Line
Flat macro under Create Binder
Edit Binder macro under Create Binder
Constant S macro under Create Addendum
Components macro under Setup of 1Step macro button
Spline macro under Create surfaces from Edit geometry button
Rib Editor
Exercise 1: Geometry cleanup for creating an addendum

This exercise uses the model files die_module_ex1.hf, die_module_ex2.hf, and
die_module_ex3.hf
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Step 1: Retrieve the file

1.
From the File menu, click on Open.
2.
Browse to the file <installation_directory>\tutorials\mfs\hf\die\Die_module_ex1.

hf.
3.
Click Open.
Step 2: Prepare the part edge geometry

Before generating an addendum surface, it is important to ensure that the part edge geometry or trim line (TL
) is sufficiently defined. Any sharp transitions or cutouts along the TL should be filled. Several geometry
creation tools are available in HyperForm for this type of preparation, which are shown in the following steps.
1.
From the View menu, click Toolbars and then select Display.
The Display toolbar menu is now displayed.
2.
Repeat Step 1 to turn on the Visualization toolbar.
3.
From the Visualization toolbar, select Geometry Color Mode and change to
By Topo .
4.
Click the User View icon
5.
In the Utility Menu, click Edit Geometry.
6.
Click the Spline button.
7.
Click the entity selector switch
8.
Click the switch in the middle of the panel and select surface only.
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and click restore1 to retrieve the saved Notch1 view.
on the left and select lines.

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9.
Verify that keep tangency is active.
10. Click on the red line as shown in the figure below and click create to make it green. This will build a
surface covering the notch.
11. From the toolbar, select the User View icon
and click restore2 to retrieve the saved Notch2 view.
12. You are still in the Spline panel. Click on the red lines as shown below to fill the surfaces.
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view.
and click restore3 to retrieve the saved Fillet corner1
14. Click on the red lines as shown below to fill the surfaces:

view.
. Click restore4 to retrieve the saved Fillet corner2
16. From the Utility Menu under Create Surfaces, click on the Sweep button.
17. In the drag geoms subpanel, click the toggle next to drag: and set it to line list. In the same row, set
the toggle to use default vector.
18. Click the toggle to set the option surface only.
19. Click the drag: line list button and click the red line as shown in the figure below.
20. Click the along: line list button and click the red line as shown in the figure below.
21. Click drag.
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22. Repeat the above two steps to close the other surface as shown below.
The next two steps are optional and can be skipped if you see all green-shared edges without any red
edges.
23. (Optional) Click keyboard F11 to jump to the Quick edit panel.
24. (Optional) Click the line panel right next to toggle edge:. With the line panel lines active, graphically
click the any interior red lines (free edges) within the circle regions in the image below. This changes the
selected red free edges into green shared edges.
25. From the Utility Menu, click on the <<<Back button. This will take you to the die module user profile
menu.
26. From the File menu, click Save and save the file as Die_module_ex1_complete.hf.
Exercise 2: Building an addendum for a flat binder

This exercise uses the Die_module_ex1_complete.hf model from Exercise 1.
Trim line (TL) is the entire outer boundary of the part. In HyperForm, you can use the Create Trim line
function to extract trim line from surfaces or meshes.
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1.
From the Geometry menu, click Line Design. Select the part boundary subpanel.
2.
Click surfs >> displayed.
3.
Click create.
Notice all the shared green edges are turned into blue suppressed edges.
4.
Click return.
Step 2: Create a flat binder

1.
From the Geometry menu, click Binder, and select the flat subpanel.
2.
Set the Offset value to 200.0 and toggle to full model.
3.
From the tool bar, click the
4.
With the yellow nodes button highlighted, click anywhere below the bottom of the model to create a
temp node.
Note:
rear view icon.
When one node is created, HyperForm generates a plane surface perpendicular and horizontal
to the screen. If two nodes are selected, a plane is created based on the two nodes, that is,
perpendicular to the screen, passing through these nodes.
Single node selected on screen for creation of flat binder surface
5.
Click create.
Step 3: Edit the flat binder
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1.
From the tool bar, click the

the binder surface.
2.
Choose the rear view icon to change back to rear view.
3.
You should still be in the Binder panel. Click the purple edit button.
4.
Select the Translate subpanel.
5.
Ensure that the switch is set to binder.
6.
Click on the switch next to N1, N2, N3 and make the direction as z-axis.
7.
Press keyboard F4 to enter the Distance panel.
8.
With N1 highlighted, hold the left mouse button and move the cursor on top of the edge of the part to
highlight it, and then click on the edge again to create a temp node N1. Refer to image below.
9.
With N2 highlighted, repeat the above step and create the temp node N2 on the binder. Refer to the
figure below. To make it easier to create N1 and N2, try changing the display to shaded graphics.
top view icon. Notice that the original part is approximately centered on
Select nodes using distance panel
10. Note the value of z dist. Remember this value.

11. Click on return.
12. This should take you back to the edit binder panel. With the noted value from the distance panel, use
the expression (Distance to translate = | Z distance measured | - 80.0) to arrive at a value so that the
distance is equal to 80mm between the binder surface and the bottom face of the part.
13. Enter that value in the Magnitude= field.
14. Click on Translate+ or Translate+ accordingly.
The end resultant distance between the part and the binder should be 80.0.
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Picture show ing the Binder and the Part
15. Click return.
Step 4: Build the addendum

1.
In the Model Browser, expand the Component folder to view the components. Right-click on
addendum and select Make Current. This changes the default working component to be addendum.
2.
From the Geometry menu, click Addendum, and select the Constant S-section subpanel.
3.
From the toolbar, click the
4.
Click on the line button next to TL:. With the line button highlighted, pick the trim line from the graphics
screen. (Trim line is the red outer boundary of the part.)
5.
Click on the surf button next to Binder:. With the surf button highlighted, click on the binder surface
from the graphics screen.
6.
Click on the purple parameters button. This will take you to the control values for addendum creation.
top view icon.
Note that the parameters for the constant S-section can be changed using the panel. The available
parameters for controlling the geometry generated include plus length, wall angle and entry radius. Other
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surface generation options include:

Plus length: A straight line section added to the outer edge of a part (10 mm default)
Wall angle: Section wall angle (15 degrees default)
Entry radius: Die entry radius (10 mm default)
Constrain plus to part: Plus length will be constrained so that it is tangent with respect to the edge of
the part (ON by default)
Enable fixed points: Fixed points will be placed along the edge of the new addendum surface if a finite
element mesh exists. If the nodes lie along the edge and are within a tolerance, a fixed point will be
generated (ON by default)
Split into small faces: Generated surfaces are divided into smaller areas in order to simplify their
definition while reading and manipulating them in other CAD systems (ON by default)
Automatically add rib at sharp corner :. HyperForm automatically puts a rib at those corners if this
option is turned on where the TL has a sharp transition (such as a corner) but without any rib.
7.
Enter Plus Length = 10.0, Wall Angle = 10.0 and Entry Radius = 10.0.
8.
Click on return.
9.
Click on create addendum.

This will create an addendum forming a smooth connection between the part and the binder surface.
10. Click return.
Exercise 3: Building an addendum for a curved binder using

the Rib Editor
The Rib Editor is a two-dimensional tool for use in the design of parametric cross-sections of an addendum
(referred to as ribs). A rib can be constructed from one or multiple basic shapes, referred to as segments.
After designing a rib, you can add it to the HyperForm model, and an addendum shape surface can later be
constructed using all of the ribs created.
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This exercise uses the model file di e_modul e_ex 3. hf .
Step 1: Load the setup file

1.
From the File menu, click on Open.
2.
Browse for the file die_module_ex3.hf.
3.
Click Open.

1.
Verify you are in the Die Module user profile.
2.
From the toolbar, click Geometry Color Mode and change it to
3.
From the Geometry menu, click Line Design.
4.
Click the surfs button and select displayed from the pop-up menu.
By Topo.
Notice all the shared green edges are turned into blue suppressed edges.
5.
Click return.
Step 3: Display a side view of the part and set the current component
1.
From the toolbar, select the rear view icon
2.
Press the keyboard - ( minus sign ) to zoom out. (You can also right-click
3.
From the Model Browser, right-click on the Binder component and select Make Current. This
changes the default working component to Binder.
.
from the tool bar.)
Step 4: Create a singly-curved binder surface

1.
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From the Geometry menu, click Binder, and select the single curve subpanel. Ensure that the toggle
switch is set to full model.

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2.
Click nodes and select several points below the part in the viewing graphics area as shown in the figure
below.
If multiple nodes are selected, HyperForm generates a singly-curved surface which passes smoothly
through the nodes and is perpendicular and horizontal to the screen.
3.
Click offset = and enter 200.0.

The binder surface will be offset by the amount specified.
4.
Click create.
Step 5: Edit the curved binder surface

There are several options available on the binder panel that enable you to modify the shape of the binder
domain. You can also edit the geometry of a binder that has already been previously created.
1.
Click the keyboard
2.
Click the edit button to enter the edit binder panel.
3.
Go to the add tracks subpanel. With the reference: node button activated, hold the left mouse button
and move the mouse cursor to a location along the binder surface edge at far most negative Y direction.
Once the line is highlighted, click again to create a temp node. Refer to the image below:
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4.
Click add. Notice a trim line is created.
5.
Repeat steps 3 and 4 and add 3 more track lines evenly distributed over the binder surface.
6.
Select the edit tracks subpanel. Then, select the add new handle radio button.
7.
Click line and graphically pick any track line.

Notice several handles (represented by temp nodes) are created on the track line.
8.
Select the move handle radio button. Notice a reference: node button appears.
9.
Click track: line and select the same track line.
10. The reference: node button is automatically highlighted. Graphically select a node on top of the track
line.
Notice the message bar says "A handle is picked successfully."
11. Graphically pick a location higher than the currently selected node. Notice the associated track line is
lifted with respect to the new location.
12. Click update to complete the editing of the curved binder.

13. Click the cast tracks subpanel.
14. For model track: line, select the track line you just modified in the previous step.
15. For candidate tracks: lines, select all the rest of the track lines.
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16. Click cast. Notice all the candidate line shapes are changed.
17. Click update.
Notice the binder surface curvature is modified.
18. Click return twice to go back to the main menu.
Step 6: Prepare to create the addendum surface

1.
From the Geometry menu, click Addendum, and select the single section subpanel.
2.
Click on the line button next to TL: and pick the trim line from the graphics screen (the trim line is the
red outer boundary of the part).
3.
Click on the surf button next to Binder: and click on the binder surface from the graphics screen.
4.
Click parameters.
5.
Click the split into small faces checkbox to de-select this option.
6.
Click the global smoothing checkbox to de-select this option.

In this exercise, a better surface quality can be obtained when the split into small faces and global
smoothing options are turned OFF. This is especially true when using multiple sections where the
transitions from one rib section to another rib section are complex.
7.
Click return.
You are still in the Addendum panel.
Step 7: Review the Rib Editor

The Rib Editor (shown below) is a two-dimensional interface for use in the design of parametric crosssections of an addendum (referred to as ribs). A rib can be constructed from one or multiple basic shapes,
referred to as segments. After designing a rib, you can add it to the HyperForm model, and an addendum
surface can later be constructed using all of the ribs created.
1.
Click rib editor.
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Rib editor graphical user interface.
There are seven main areas in the Rib Editor window:

Tabs
There are four tabs to choose from.

The Options tab displays a list of options to display, constrain, or edit the ribs. Under
this tab you have the following options:
Plus value:
A straight line section added to the edge of a part. (10 mm default)
Last Wall
angle:
Section wall angle. (15 degrees default)
Die Entry
radius:
10 mm default
When the plus value, last wall angle and Die Entry radius are enabled, you activate the
global values. Any appended rib segments will use the activated values as default. For
example, if you activate plus length value = 10.0, any further added new plus line
segment in Rib Editor will have straight segment = 10.0 as default.
Constrain to
part:
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Activate this option to constrain the rib so that it is tangent with

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Constrain to
Binder:
Activate this option to constrain the rib so that it is tangent with

respect to the edge of the Binder.
Enable
Handles:
Activate this option to create a center for the curved portion of the ribs
on the graphics screen. This allows you to change the curvature value
by holding the yellow center button with left click.
Show Scales: Activate this option to mark the graphics screen with scales.
Show
neighboring
ribs:
This function displays neighboring ribs, if any exists.
Show part
profile:
Activate this option to show the profile of the part along with the rib
being created.
The Model tab provides the total number, names, and parameters of the segments
that constitute the current rib.
The Library tab allows you to load a file containing pre-existing shapes. You can then
retrieve the different shapes from the loaded library to construct a rib. New shapes can
also be added to the library file.
The Help tab shows the description of the Rib Editor.
Plot area
Graphics display area for the ribs
Action buttons
There are five action buttons.

Append
Adds a rib at the end of an existing rib
Insert
Adds a rib at the start of an existing rib
Replace
Replaces an existing rib with a new rib
Delete
Deletes a rib
Undo
Enables undo operation to the previous action
Note: The current action mode is displayed on the toolbar directly above the action
buttons.
Toolbar
The toolbar is composed of icons representing four basic shapes that can be used to
construct a rib (in addition to the library shapes):
Plus
Straight segment with length and angle
Fillet
Fillet with radius and span
Half-S-Shape Straight segment with a fillet at the end

S-shape
Composite shape consisting of 3 straight segments and 2 fillets
B-shape
Composite of two s-shapes (also called the draw bar)
Note: The parameters for the toolbar shapes can be changed in the parameter display
area (described below) or through the dragging and dropping of control points from the
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options page.
Parameter
display area
Located in the area between the tool and status bars, the parameters of shapes can
be viewed and modified here.
Status bar
Located at the bottom of the Rib Editor window, the status bar displays messages
concerning geometric constraints used during rib construction.
Viewing options Several viewing options are offered in the lower right-hand corner of the window; such
as zoom in, zoom out, and fit.
2.
Verify that only Constrain to part and Show part profile are activated.
If show part profile is off, click the Options tab and select the ON check box next to the Show part
profile option. This will show a part profile in the display area as a red dotted section line.
3.
Right-click the zoom-out
4.
While pressing the Ctrl key, use the left mouse button and draw a circle in the plot area to zoom into
the area shown in the following figure.
button twice on the viewing options bar.
Note: You can also do it by clicking on Circle Zoom
function from viewing options.
The part profile (red), part edge tangency (orange arrow) and the binder profile (light blue) are shown in
the image above.
5.
Click Append
. Notice status "action mode : Append" is displayed above action buttons.
This allows you to add any new shape to part edge tangency.
6.
Click the Plus icon

Note:
on the toolbar to append a plus section to end of part.
A straight-line section tangent to the edge of the part is added as shown in the figure below.
Notice the two parameters Length and Angle are defined in the parameter display area.
Also, notice the current action mode: is still set to Append. The append mode ensures that any new
rib created will be added to the end of the currently highlighted section. You can also change the action
mode: to Insert, Replace or Delete. You will continue this exercise with the action mode: set to
Append.
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Plus length added
7.
From the parameter display area, change Length: from 10.0 to be 3.0.
Notice the length is reduced in Plot Area.
8.
Click the Fillet icon
9.
From the parameter display area, change Radius: from 10.0 to be 5.0.
10. Click the S-section icon
on the tool bar to append a fillet section to the end of the plus section.
on the toolbar to append an S-section to the end of the fillet section.
11. From the parameter display area, change all parameters for the S-Section as in the image below:
Note: Click on the icon, using the left mouse button and zoom into the area to have a larger graphical
view.
12. Check the Constrain to binder option.
Notice the S-section is extended and attached to the binder profile. The parameters are also adjusted.
This ensures that the rib is tangential to the binder surface.
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13. Click the Options tab and select the ON check box next to the Enable handles option. This allows you
to graphically change any of the rib sections.
Handles turned ON
14. Hold the left mouse button and move the mouse cursor on top of the handle.
15. Notice the handle is changed to red color. A message box is also displayed in Plot Area as "First
segment of S shape, length :3.0, angle: 20.0".
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16. Keep holding the left mouse button and graphically drag the mouse cursor. In this step, it is NOT
required to exactly follow the parameters below.
Notice the first segment is extended and also parameters are updated accordingly.
17. Once the rib is defined, close

the Rib Editor window. HyperForm remembers the shape of the rib
and will apply it when you create the addendum.
18. From the tool bar, click comp: and select the addendum component. This allows HyperForm to set
the addendum component to be the working component.
19. Click create ribs. Notice ribs are generated.
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20. Click create addendum to create the addendum surface.
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The Modify Addendum panel allows you to parametrically modify the addendum geometry created in the
Addendum panel. Essentially, it provides you with highly efficient tools to change the rib parameters by
either dragging at the rib ends or modifying the geometry or location of the binder.
Modifying a portion of a rib ensures that the whole rib definition is carried over to the new location. More ribs
can be added to the addendum to improve the quality of the generated addendum. This allows for local
refinement of addendum surfaces without having to reconstruct the addendum surface. After new ribs are
modified or added, the addendum surface can be updated by the Addendum panel/multiple sections to the
new definition automatically.
In this exercise, you will learn:
How to modify addendum
How to add more ribs to an existing addendum
How to absorb new modified ribs and update addendum surface
Tools
Addendum panel
Modify Addendum panel
Exercise: Modifying the Addendum Cross Section for a

Controlled Flow of Metal
This exercise uses the model file Modify_an_addendum.hf.
Step 1: Load the model file and select shaded mode

1.
From the File drop down menu, click Open....
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2.
Browse for the file Modify_an_addendum.hf.
3.
Click Open.
4.
From the tool bar, click the Shaded geometry and surface edges button
for shaded mode.
Step 2: Modify the addendum by increasing the wall angle

1.
From the View menu, select Toolbars and select Display. This will enable the Display toolbar.
2.
From the tool bar, select the user view icon
3.
From the Geometry menu, click Modify Addendum. Select the edit binder subpanel, and click on
update.
. Click on the restore1 button to retrieve a saved view.
This will create the latitude lines and update the model to the 11.0 version.
4.
Select the drag rib end subpanel.
5.
Select the ribs shown in the image below.
6.
Verify the toggle is set to modify last wall angle to select the method to use for modification of the
addendum.
Note:
7.
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modify plus will extend the plus tangent to the part.

modify last wall angle will change the angle of the last draw wall.
Click get handle to activate the handle (yellow circular ball) at the rib ends.

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8.
Click move handle.
9.
Hold your left mouse button and move the mouse cursor on top of one of the handles in the graphics
region. Keep holding the left mouse cursor and move the handle in the outbound direction on the binder
surface.
Refer to the image below:
10. Click update to pass the rib ends through the handles and modify the addendum surface to pass through
the modified rib sections.
Notice the outer shape of the addendum is modified accordingly. The edit addendum panel allows a
quick update over the shape of addendum by dragging the handles.
11. Click reject to get back to the original configuration.
12. Click clear handles to remove the existing handle.
This process can be repeated to modify the plus value.
13. Click return.
Step 3: Modify the addendum using the latitude feature

1.
From the Geometry menu, click Addendum and click the single section subpanel.
2.
With the TL: line button highlighted, select the trim line and the binder surface as shown below:
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3.
Click on edit latitude lines. You will be taken to a new panel as shown below where you can drag the
latitude lines interactively to change the cross section of the addendum. The red lines you see below are
latitude lines.
4.
With the latitude lines highlighted, click on the red lines as shown below:
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5.
Click on the second Lines button against Fixed Ribs: and select the fixed ribs as shown below:
6.
Click on the get handle button. Notice the two handles on the Latitude Line as shown below:
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7.
Click on move handle. Click and drag one of the handles either in the z direction or in the XY plane.
8.
Click on update. Notice that the cross section of the addendum changes.
Step 4: Modify the addendum by adding ribs
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1.
From the tool bar, select the user view icon
2.
You should still be in the Modify Addendum panel. Select the add rib subpanel.
3.
Click line button and elect the rib to be copied as indicated in the image below.
4.
Click the nodes button, keep holding the left mouse button, and move mouse cursor over the nodal
location as indicated in the image below. Release the mouse button and click the left mouse button
again to create a temp node.
5.
Click add.
. Click restore2 button to retrieve the saved view.
This will copy the rib and also modify the addendum surface to pass through the new rib. The figure
below shows the addendum surface before and after adding the rib.
Step 5: Review the addendum rib

1.
Select the edit rib parms subpanel.
2.
Click the line panel and graphically select the rib as shown in the image below.
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3.
Click rib editor.
4.
Graphically click the green rib as shown in the image below until it becomes white in color.
Note: All the parameters are displayed and can be modified and updated.
Step 6: Modified ribs and update addendum surface

1.
In the Rib Editor, change the Radius 2: from 10.0 to 15.0. Notice the selected rib is also graphically
changed.
2.
Close the Rib Editor.
3.
Click update.
Notice the rib and the associated addendum surfaces are updated.
4.
Click return.
Step 7: Absorb new modified ribs and re-create addendum surfaces using multiple
sections
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During previous steps, some ribs are modified and some addendum surfaces are split. In this step, you will
remove the split addendum surfaces by re-creating the addendum surfaces using existing ribs.
1.
Press F2 on the keyboard to open the Delete panel.
2.
Click the toggle and change the selector to surfs.
3.
Click surfs and select by collector.
4.
Select the addendum component and click select.
5.
Click delete entity to delete all addendum surfaces.
6.
Click return.
7.
From the Utility Menu, under Create Addendum, click on Multiple.
8.
Click the toggle next to POL: and set it to with POL.
9.
Click parameters and disable both split into small surface and global smoothing.
10. Click return to go back to the multiple sections subpanel.

11. Select the Binder surface, TL and POL line as shown in the image below.
12. Click create addendum.

Notice that new addendum surfaces are created.
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HF-2040: Parameterization of External Binder and Addendum

Section Using Section Editor
In this tutorial, you will learn how to parameterize binders and ribs using the Section Editor in HyperForm.
The Section Editor provides an easy method of parameterizing binders and ribs (addendum cross-sections)
that were created in a system outside HyperForm, such as Catia or AutoForm. You can modify the geometry
of the cross-sections, or integrate them to create a parametric addendum that can be generated by
HyperForm.
Tools
This tutorial uses the Section Editor, which can be accessed by:
the Section Edit panel
the Edit Section macro
Exercise: Using the Section Editor

This exercise uses the model file section_editor_part.hf and geometry files external_binder.
iges and external_section.iges
Step 1: Open the model file

1.
From the File menu, Open.
2.
Browse to the section_editor_part.hf file.
3.
Click OK.
Step 2: Import the binder data

This model has a binder associated with it that is in IGES format. Your goal is to raise the binder locally to
create a curvature, thereby reducing the draw depth in the raised area of the part.
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1.
2.
Click the Select files... icon
3.
Click Import. The geometry appears below the part in the graphics area, as shown below.
4.
Click Close to close the Import tab.
and select the Import Geometry icon
and browse to the external_binder.iges file.
Step 3: Mesh the binder

To make future updates to the binder easier, it is recommended that you mesh the binder.
1.
2.
Right-click on lv3 and select Rename. Enter the new name as Binder. Right-click on it again and
select Make Current.
3.
From the Mesh menu, click R-Mesh to open the Rigid Tool Surface Meshing panel.
4.
Accept the default values.
5.
Click Mesh
6.
Select the binder surface in the graphics area and click proceed. HyperForm creates mesh on the
binder surface.
7.
Click Close.
Step 4: Create the cutting plane

1.
From the toolbar menu, click User Views
2.
From the main menu, click section edit.
3.
Click elems and select displayed from the extended entity selection menu.
4.
Using the N1, N2, N3 and B selectors, select three nodes and a base node to define the cutting plane,
which corresponds to the raised area of the part. Refer to the image below.
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5.
Click create section.
Step 5: Use the Section Editor to modify the binder

1.
Click edit section.

The Section Editor opens in its own window. This editor displays a parameterization of the cut you
made in step 4. The parameterization is composed of multiple lines, which are listed in the Model
Browser. Specialized options are available in the Section Editor to manipulate the cross-section.
2.
With the Joints option selected, right-click the joints that are not endpoints to convert them to points.
(Joints are red solid circles and points are blue hollow circles.) Removing the joints causes the section to
become a straight line.
3.
In the Radius subpanel, click and drag the section to the appropriate location to specify the peak of the
desired curvature of the section.
4.
When you are satisfied with the curvature of the section, close the Section Editor and return to the main
panel of HyperForm. The modified section is shown in blue in the graphics area. (The original location is
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shown in green.)
Note:
line.
5.
The green line is the original cross-section. The new target cross-section line is the blue
Click return to go back to the main menu.
Step 6: Morph the binder to pass through the modified cross-section

1.
From the Applications menu, select HyperMorph.
2.
From the main menu, click map to geom.
3.
Set the left-most toggle to line difference.
4.
For from line: select the original, green line. For to line: select the modified, blue line. These selections
indicate that the original line will be morphed to the location of the blue line.
5.
In the same panel, switch map domains to map nodes.
6.
Click nodes and select by collector.
7.
Select binder to select all the nodes in the collector that correspond to the binder.
8.
Click map. The mesh is mapped.
9.
Click return.
Next you must map the surface.
10. From the main menu, select Morph.

11. Select the morph surfaces subpanel and click morph surfs. The binder surface has now been updated
to pass through the parametric cross-section.
12. Click return twice to close the panels.
Step 7: Import the geometry file containing ribs

1.
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and select the Import Geometry icon

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2.
Click the Select files... icon
3.
Click Import to import the file.
and browse to the file external_section.iges.
Notice an addendum rib is imported.
Step 8: Create a collector to contain the new surfaces

1.
Right-click anywhere in the white space in the Model Browser and select Create and then select
Components, as shown below.
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2.
Type the name as addendum and choose a color.
3.
Click create.
Step 9: View and export the rib

1.
From the Utility Menu, click on the Edit Section button.
2.
Set the entity selection menu to lines.
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3.
In the graphics area, select the rib and click edit section.
4.
The Section Editor opens. Note that the rib is already parameterized and is composed of arcs and
lines, as listed in the Model tab.
5.
On the Export tab, enter save1 in the Current section: field and click Save.
The rib section appears in the list.
6.
Close the Section Editor and click return to close the Edit section panel.
Step 10: Create the parametric addendum

1.
From the Geometry menu, click Addendum and select the single section subpanel.
2.
Select the outer edge of the part for the trim line (TL field) and the outer edge of the binder for the Binder
field.
3.
Click rib editor. The Rib Editor opens in its own window.
4.
Click the Library tab and note that the save1 rib appears in the list.
5.
Click the rib name in the list and note that a preview of the rib appears in the left side of the Rib Editor
window, where you can see the geometry, including the parameters you created.
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6.
Click the Append button to change the action mode, and then click the library button
rib to the parts geometry. Note that the rib extends beyond the binder surface.
7.
In the graphics area, double-click the last segment of the rib to select and highlight it. The segment
beginning beyond the binder boundary will be deleted.
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8.
Click delete to delete the segment.

In steps 9 through 12, you will modify the last sections length and angle so that the rib does not cross
the binder. Then you will constrain the rib to the binder.
9.
In the graphics area, click the last segment as shown in the image below.
10. For Length:, change the value from 24.2 to 10.0 and press Enter.
Notice the last segment is no longer passing the binders boundary.
11. Click the Options tab.
12. Check the Constraint to binder checkbox.
13. Notice the rib is adjusted so that it can attach to the binder.
14. Close the Rib Editor, which will return you to the Addendum panel.
15. Click create ribs. HyperForm automatically creates ribs based on the parameters you have set.
16. Click create addendum. HyperForm creates the addendum.
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Step 11: (optional) Save the model as section_editor_part_complete.hf
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Optimization
The following Optimization tutorials are available:

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The HyperMorph module allows you to alter models in useful, logical, and intuitive ways while keeping mesh
distortion to a minimum.
With the help of HyperMorph, you can rapidly make smooth changes to die geometry parameters like the
draw wall angle. The morph volume feature creates a volume around a group of elements, which allows you to
morph to the desired shape by dragging the handles at the corners of the volume.
This tutorial assumes that you are familiar with HyperForm functionalities and the HyperMorph module.
Information on HyperMorph topics can be found in the online help.
Tools
This tutorial uses the HyperMorph module, which can be found in the Tools menu.
Exercise: Morphing the die using HyperMorph

This exercise uses the model file form_tutorial.hf.
Step 1: Load the user profile

1.
2.
For Application, select Manufacturing Solutions. Verify that HyperForm and Radioss One Step are
selected.
3.
Click OK.
4.
Click return.

1.
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2.
Browse to the file <installation_directory>\tutorials\mfs\hf\1step\form_tutorial.

hf.
3.
Click Open.
Step 3: Create the morph volumes

Morph volumes within the HyperMorph module allows you to enclose a given mesh with morph volumes, alter
the morph volumes to fit your model, and then change the shape of your model by modifying the morph
volumes.
1.
From the Applications menu, select HyperMorph.
2.
Select the morph volumes button on the main menu.
3.
Select the create subpanel.
4.
Use the switch
5.
Enter the following values:
to select create matrix.
X density = 2
Y density = 10
Z density = 1
buffer % = 5
6.
Uncheck auto-tangent. Keep all the other settings as they are.
7.
Click elems and select displayed.
8.
Click create.
The entire part is enclosed in twenty hexagonal morph volumes. These twenty morph volumes are the
result of 2 x 10 x 1 input for X, Y and Z in the create matrix as shown in the figure below. Red color
handles are created at the end corners of each of the twenty boxes.
8.
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Select the split/combine subpanel.

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9.
Ensure that the selection of the left top toggle is split mvols.
10. Keep all the other settings as default except uncheck the box for make tangent.
11. Pick the edge close to the black X as shown in the figure below and type in 0.62 in the box for single
split.
12. Click split.

As a result of this split, ten more morph volumes will be created. The split is propagated to the other end.
Red color handles are created at the corners of the morph volumes.
13. Click return to exit from the Morph volumes panel.
Step 4: Morphing the die

1.
From the main menu, select Morph.
2.
From the header bar, select the user view icon
3.
Click rear to change to rear view.
4.
Select the move handles subpanel.
5.
Make sure the top selector is set to translate mode.
6.
Make sure the middle selector is set to along xyz.
7.
Use the following values:
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X=0
Y = -20
Z= 0
8.
Click handles.
9.
Click handle again and select by window from the popup window.
10. With the points button activated, draw a window as shown in the image below.
Handles selected by w indow option
11. Click select entities.

12. Click select again to go back to the Morph panel.
13. Click morph. The die after morphing is shown below.
Step 5: Record the morphed shape sh1

1.
Select the save shape subpanel.
2.
For name =, type sh1.
3.
Toggle the as handle perturbations selection to as node perturbation.
4.
Click save.
5.
Click yes to the message window "Save perturbations for node at global and morph volume handles? (y/
n)"
6.
Click undo. This will recover the model back to original model shape.
Step 6: Morph the second shape

1.
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2.
Use the values:

X=0
Y = 20
Z= 0
3.
Click handles.
4.
Click handles again and select by window from the popup window .
5.
With the points button activated, draw a window as shown in the image below.
Handles selected by w indow option
6.
7.
Click select to go back to the Morph panel.
8.
Click morph. The die after morphing is shown below.

1.
2.
3.
Verify the toggle is set to as node perturbation.
4.
Click save.
5.
Click yes.
6.
Click undo.
Step 8: Morph the third shape
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1.
From the tool bar, click on the user view icon
2.
Click the left view from the pop up window.
3.
4.
Use the values:
X = -20
Y= 0
Z= 0
5.
Click handles. You are now in entity selection mode.
6.
Click handles again and select by window from the popup window .
7.
With the points activated, draw a window as shown in the image below.
8.
9.
Click select to go back to the Morph panel.
10. Click morph. The die after morphing is shown below.

1.
2.
3.
Verify the toggle is set to as node perturbation.
4.
Click save.
5.
Click yes.
6.
Click undo.
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Step 10: Apply all saved shapes

1.
Go to the apply shapes subpanel.
2.
Click shapes and select the three saved shapes.
3.
Click select.
4.
For multiplier, keep the default value, 1.0.
5.
Click apply.
All the three shapes are applied together.
6.
Click on the save shape subpanel and enter the name as combine for the combined shapes.
7.
Click save.
8.
Rotate the model to see the results.

The resultant shape change of the part is shown in the figures below.
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Return to Optimization Tutorials
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This tutorial guides you through the set up of an optimization study using the link between HyperForm and
HyperStudy. Familiarity with HyperForm and HyperMorph is required.
Stamping processes typically deal with large number of shape and process design variables. In order to
automate the process of arriving at an optimal choice of design variables, a link between the analysis
program and the optimization program is essential. The process variables are set up from HyperForm panels.
The shape variables are set up with the help of HyperMorph, a mesh morphing tool. The example used here
utilizes HyperForms One-Step analysis (Radioss) solver, but the same process can be easily extended to
an incremental forming analysis.
A quality function that minimizes failure by tearing or wrinkling has been developed using the major and minor
strain ratios corresponding to the formability zones under a forming limit diagram. The objective function is to
minimize the distance between the major and minor strain coordinates for each material point in strain space
and the curve describing the quality function as illustrated in the figure below.
Quality function for minimizing formability defects
The shape variables are the blank edge profile. The die entry radius, the part depth, and the process variables
are the blankholder force and the drawbead restraining forces as illustrated in the following figure.
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Distribution of design variables
This tutorial assumes that you are familiar with the basics of optimization and HyperStudy.
Step 1: Load the HyperForm One-Step environment file

1.
2.
For Application, select Manufacturing Solutions. Verify that HyperForm and Radioss_One_Step are
selected.
3.
Click OK.
Step 2: Load the HyperForm model file

1.
2.
Browse to the file <installation_directory>\tutorials\mfs\hf\Opti\part1b_opti.hf.
3.
Click Open.
Step 3: Launch HyperStudy and set up the study

1.
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From the Applications menu, select HyperStudy. This opens a new dialog.

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2.
Click on Add Study button.
3.
Select New from the drop-down menu.
4.
The Add Study dialog is displayed. Accept the default values and click OK.
5.
Select your working directory as Study directory using the file browser
window.
6.
Click Next > to continue the Create models window.
7.
Click Add Model.
8.
Select Model type: HyperMesh from the drop-down menu.
9.
Click OK.
in the upper right of the
A new model is added to the list. Notice the Solver is set to Radioss.
10. Click Next > to continue to the Design Variables dialog.
11. Click Add Model Parameter.
The Model Parameters dialog opens.
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12. In the model tree, open the Shape, Drawbead, and Blankholder collectors.
13. Hold down the ctrl key and left-click to select all shapes, drawbead variables and blankholder variables,
except bh.friction.
14. Click Add. Notice all the selected variables are passed to the location under HyperStudy Parameters.
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15. Click OK.

You return to the HyperStudy dialog.
16. Click the blank space to the left of each row, which contains information pertaining to a shape variable.
17. Type 1.0 in the Lower bound: text box for all shape variables.
18. Type 1.0 in the Upper bound: text box for all shape variables.
19. Click the blank space left next to rows which contain information pertaining to drawbead restraining
forces (db1.restraintforce, db2.restraintforce, db3.restraintforce) and blankholder tonnage (bh.
tonnage).
20. Repeat steps 17 and 18 using a Lower bound: of 0.0 and an Upper bound: of 200.
21. Click Next > to continue to the Do nominal run window.
22. In the Solver input file field, enter part1b_opti.parm.
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This is the name of the input file created by HyperStudy for the RADIOSS solver.
23. Choose Radioss from the drop down menu as the Solver execution script.
The input to HyperForm will be part1b_opti.parm. You do not need to edit the Solver input
arguments field.
Step 4: Perform the base run

1.
Click Write and then Execute.

or
Write/Execute.
2.
When the operation is complete, a message is displayed: End executing model(s) for
approach ( Nom_1() )
3.
HyperStudy calls the RADIOSS solver to solve the model file without applying any design variables. This
is called a nominal run. A nom_run directory is created inside the study directory. The data to evaluate
the objective function is available under the file part1b_opti_opt.dat. The constraint can be
evaluated from the data under the file part1b_opti.dat. These two files are the output of the nominal
run.
4.
Click Next >.
Step 5: Create a response that corresponds to the objective function

1.
The Create responses panel is displayed.
2.
Click Add Response.
3.
Click OK to accept the default values.
4.
Verify that the box next to Response_1 is checked.
5.
Click Expr Builder.

The Response Expression Builder is displayed.
6.
On the Vectors tab, click Add.

This adds a result vector called Vector 1.
Step 6: Define the vector

1.
Click the browser button

under the Vector resource file field and select the part1b_opti_opt.
dat file from the /study directory/nom_run/m_1/ directory.
2.
Define Vector 1 by choosing the following options from the pull-down menus in the lower right-hand
section of the Vectors tab:
Type:
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Request:
FLD
Component:
Distance 1
3.
Click Apply to use this vector in the Response expression field.
4.
Click in the Response expression field window and enter the following expression: sum(v_1*v_1).
The meaning of this expression is: take a sum of the squares of the distance between each strain
coordinate and the quality function.
5.
Select the Evaluate expression check box.
6.
Notice the function sum (v_1*v_1) is changed to a value of 55.8369.
7.
Click OK.
Step 7: Create another response corresponding to the constraint

1.
Repeat the previous steps to create a second response -- Response_2 and click Add to create Vector
2.
2.
Click the browser button under the Vector resource file field and select the part1b_opti.dat file.
3.
Define Vector 2 by choosing the following options from the pull-down menus in the lower right-hand
section of the Vectors tab:
Type:
HyperForm Results
Request:
FLD
Component:
Thickness Strain
4.
Click Apply to use this vector in the Response expression field.
5.
Click in the Response expression field window and enter the following expression: mean(sort(1,
v_2)[0:49:1]).
The meaning of the this expression is : 1) sort all the elemental thickness values in descending order, 2)
extract the top 50 values, and 3) calculate the mean of those values. The result is a scalar representing
the mean value of the top 50 thickness strain values in the model.
6.
Select the Evaluate expression check box.

The expression mean(sort(1,v_2)[0:49:1]) should change to the corresponding value 45.022
7.
Click OK.
This completes the Study setup. You can now proceed to the desired study type whether it is a DOE,
Optimization, or Stochastic study.
Step 8: Bypass link design variables and sensitivity analysis

HyperStudy can perform design variables linking and sensitivity analysis. In this exercise, you will bypass
both and perform only optimization study.
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1.
Click Next > to continue to the Link design variables window.
2.
Click Next > to continue to the Sensitivity window.
Step 9: Run the optimization study

1.
Click Continue to and select Optimization study.

Or simply click the blank box for Create optimization in the navigation tree.
2.
Click Add Optimization.
3.
Click OK on the dialog box accepting the default values.
4.
Select Adaptive response Surface Method from the pull-down menu next to Optimization Engine.
5.
Click Next to continue to the Design Variables dialog.

This allows you to review your design variables.
6.
Click Next > to continue to the Constraints dialog.
7.
Click Add constraint.
8.
Click OK.
9.
Choose Response_2 in the Apply constraint on: field.
10. Click <= (less than): and type 25 under bound value.
This is to specify that the average of the thinning strain for the regions with the highest stretch levels
should be less than 25 percent. Such constraints are necessary to avoid localized defects which can
occur if an objective function, like the one used here, based on the whole model is left unconstrained.
11. Click Next > to continue to the Define objective dialog.
12. Click Add objective.
13. Click OK.
14. Select Response_1 from the Apply On drop-down field.
15. Select Minimize in the Goal drop-down field.
16. Select 100 for Maximum number of iterations:.
None of the other parameters need to be altered.
17. Click on the Advanced Parameters tab.
18. For the On failed analysis column, select ignore failed analysis.
When ignore failed analysis is selected, optimization takes a step back and attempts another
analysis when a failed analysis is detected.
19. Click Launch Optimization to launch the optimization.
20. Click Yes to A message window display "Do you wish to sk ip the solver run for starting point and extract
results from _nom run".
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An information window informs you about the way the optimization is run. Either interactive mode or
batch mode is possible. The mode can be changed by using the Tools drop down menu on the
HyperStudy menu bar and selecting Job management, and then Optimization Study.
21. After the optimization has finished, continue from the Post-processing window.
Step 10: View the iteration history of the optimization study

In each of the tabs; Obj & Consr., DV, and Responses boxes are displayed with the labels of their
respective functions.
1.
Click a check box to display the appropriate iteration history.
Step 11: View the results of the optimization study

1.
Open the file opti_1.hyperopt from study directory and go to the end of the file to find the iteration
number that corresponds to the optimal design.
2.
Open HyperForm and import the part1b_opti.parm file from the directory that corresponds to the
optimal run.
3.
From the Run Analysis panel, click load results.
4.
Create fld plots and compare it with the initial run.
5.
(optional) Save as a HyperForm model file.
Return to Optimization Tutorials
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Result Mapping
The following Result Mapping tutorials are available:
HF-5000: Using Results Mapper in HyperCrash

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HF-5000: Using Result Mapper in HyperCrash

In this tutorial, you will learn the procedure for mapping forming results onto structural models using the
HyperWorks Results Mapper.
In real time practice, you may come across situation where the end results of formed parts have to be
considered when it goes as a part of an assembly for structural analysis to depict a more realistic situation.
To achieve this, HyperWorks Results Mapper is used.
HyperWorks Results Mapper (HWRM) is a HyperCrash based tool that provides a framework to initialize a
structural model with results from a forming simulation. You will go through a simple procedure loading the
structural model and forming simulation results followed by mapping the results and finally exporting the
mapped data in a structural solver format. For output, the structural solvers currently supported are RADIOSS
Y, Radioss STA, ABAQUS and Radioss BULK. The results are transformed as necessary if the forming and
structural models are in different co-ordinate frames.
In this tutorial, you will first import the structural model and find a region on it which is almost similar to a
region on the formed component. This region identification is the reference for the Results Mapper. Then, you
will import the results of the formed component, identify the same region, and map the forming results to the
structural model.
This tutorial assumes that you are familiar with HyperCrash. If you need help on these topics, please refer to
the corresponding tutorials in the online help.
Results Mapper can be accessed by clicking Start > Altair HyperWorks 11.0 > Manufacturing Solutions
> Results Mapper.
Exercise: Mapping the forming data from a STA file onto a Radioss mesh
This exercise uses the models:
EndOfFormingResults.sta
MeshToBeMapped_0000.rad
MeshToBeMapped_0001.rad
Step 1: Load the structural model into HyperCrash

1.
Click Start > Altair HyperWorks 11.0 > Manufacturing Solutions > Results Mapper
2.
In HyperCrash, click on File, then click Import and select Radioss, as shown in the figure below.
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3.
Browse and locate the file MeshToBeMapped_0000.rad. Click OK to open the file.
4.
The Import Choice for Units dialog is displayed. Click on Ignore and Import.
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5.
Click on Process and then select Results Mapper from the menu, as shown below.
This will bring up Results Mapper inside HyperCrash as shown below.
Step 2: Load the STA file into HyperCrash
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1.
Click on the Load Stamping File icon
2.
Click on Radioss and browse and locate the file EndOfFormingResults.sta.
3.
Click on the file and click OK to bring the file into the session.
4.
Click on the model name as shown in the red box below to highlight it and click on the glasses icon
to display the model in the small screen.
inside the Result Mapper.
Step 3: Position the STA file to align it with the target model
Upon loading the files, the STA file, which is in the forming coordinate system, and the target model, which is
in the car coordinate system, appear on top of each other as shown below:
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1.
Click on the Positioning button.
2.
Click on the third option, as shown in the red box below:
3.
Click on the arrow next to node Id below the header First couple of nodes.
4.
Pick the first node on the horizontal model shown on the left hand side of the image below.
5.
Rotate the model by ~90 degrees (press and hold the Ctrl button and left mouse button, move the mouse
to rotate) to make the second selection as shown on the right hand side of the image above.
6.
Follow steps 4 and 5 to select 2 more corner node pairs as the second couple of nodes and the third
couple of nodes. Refer to the image below:
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7.
Click on Optimize.
8.
Click on Allow Rotation.
9.
Click on Apply move.
10. Click on Ok in the bottom left hand corner to validate and accept the positioning.
Step 4: Map the results from STA mesh to structural mesh

1.
Click on the include picked part icon
2.
Graphically select the structural model from the screen. The selected part name is displayed within the
Results Mapper in the right hand column.
3.
Click Yes on the right hand bottom corner of the screen as shown below.
4.
Click on Map Results at the bottom of the Result Mapper. The results are mapped and are shown in
the Results Mapper area.
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Step 5: Change result type and export mapped mesh

1.
Click on the Contour tab.

At this point, you may need to expand the Results Mapper tab by dragging the right side bar further out.
This will enable you to see the entire Contour tab of the Results Mapper.
2.
In the Type of Value: field, select Plastic Strain from the drop down menu.
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Notice that the mapped data changes to Plastic Stain both for STA mesh and the structural mesh.
3.
Use the arrows in the On integration point: field to change the value in the box. Notice that the mapped
result type is automatically updated with the new data.
4.
Click on the Output tab.
5.
Click on the Browse button.
6.
Navigate and select the destination folder.
7.
Type PlasticStrain.inp in the field and click on OK.
8.
In the File Format field, select Abaqus.
9.
Make sure the Thickness, Plastic Strain and Stress Tensor fields are checked.
10. Click on Export. The file is exported.
Return to Result Mapping Tutorials
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In this tutorial, you will learn the procedure for mapping forming results onto structural models using the
HyperWorks Results Mapper.
In real time practice, you may come across situation where the end results of formed parts have to be
considered when it goes as a part of an assembly for structural analysis to depict a more realistic situation.
To achieve this, HyperWorks Results Mapper is used.
HyperWorks Results Mapper (HWRM) is a Process Manager-based tool that provides a framework to
initialize a structural model with results from a forming simulation. A Process Manager template takes you
through a step-by-step approach starting from loading the structural model and forming simulation results into
Fepre and HyperView respectively, followed by choosing the data to map and finally exporting the mapped
data in a structural solver format. Any scalar, vector or tensor data that can be read into HyperView can be
chosen for mapping. For output, the structural solvers currently supported are RADIOSS (Bulk Data Format)
and OptiStruct, Nastran, LS-DYNA and Abaqus. The results are transformed as necessary if the forming and
structural models are in different co-ordinate frames. Some amount of geometric difference between the
forming and structural model is tolerated.
In this tutorial, you will first import the structural model and find a region on it which is almost similar to a
region on the formed component. This region identification is the reference for the Results Mapper. Then, you
will import the results of the formed component, identify the same region, and map the forming results to the
structural model.
This tutorial assumes that you are familiar with HyperView. If you need help on these topics, please refer to
the corresponding tutorials in the online help.
Note:
Starting version 11.0, HyperWorks Results Mapper is in maintenance mode. Results Mapping
Using HyperCrash is recommended as a general purpose mapping tool.
Tools
To do results mapping using the Process Manager, first launch HyperView and then load the Process
Manager template file. Once the template file is loaded, the tutorial can be completed.
Exercise: Mapping Forming Analysis Results onto Structural

Models
This exercise uses the model files mapping.hf.
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Step 1: Launch HyperView and load the template

1.
Launch HyperView by clicking Start > Programs > Altair HyperWorks > HyperView.
2.
Click View > Browsers > HyperWorks > Process Manager.
3.
Click in the Load template: field and select Browse...
4.
Navigate to the following location <installation_folder>\hw\tcl\fepre\hwrm and select the

file hwrm.pmt.
5.
Click Open.
6.
In the Create/Open Process Instance dialog, enter a name and location in the appropriate fields to
create a new instance.
7.
Click Create/Open.
Step 2: Load the structural model

1.
In the Type: field, select HM/HF (the structural file format).
2.
Click Browse next to the File name: field and select the file containing the structural model mapping.hf.
3.
Click Import. The application automatically switches to HyperMesh and the User Profile dialog opens.
Accept the default user profile and click OK.
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Notice the structure file is imported into the Process Manager tab. The first step is checked with a
green mark indicating its completion.
Step 3: Select the structural part and its orientation for mapping
1.
Make sure the Components button is active. Click on Components and graphically select any element
from the displayed component to be mapped.
2.
Click the top view icon
3.
Click the node list button and select three nodes and a base node on a region of the selected
component so that the same region can be identified on the component from forming analysis. The
image below shows the location of the nodes on the structural model.
4.
Click Apply.
to change to top view.
Notice the second step is checked on the Process Manager tab.
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Step 4: Load the forming results model

1.
In the tutorial folder, unzip HWRM_forming_result.zip. All the D3PLOTXX files form analysis results
previously created by LS-DYNA into the same folder.
2.
For both the Model file name: and Result file name: fields, click Browse and select the d3plot file
from the forming simulation, as shown in the image below.
3.
Click Import.
Note:
The operation opens a second window in HyperWorks Desktop. The window on the left
(HyperMesh) contains the structural model and the right window (HyperView) contains the formed
component.
Step 5: Display the formed part

For this set of steps, make sure the HyperView window is the active window. With the blue halo surrounding
the forming result window (right window), by the following:
1.
360
Click on the Results tab to open the Results Browser.

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2.
Expand the Components folder. Right-click on Shell 2 and select Isolate to turn off the display of all
components except the blank (or the formed component).
3.
Click on the Shaded Elements and Mesh Line icon

component.
4.
Click the top view icon
to turn on the mesh for the displayed
to change to top view.
Notice the structure and forming mesh are different as shown in the image below.
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Step 6: Select mapping parameters on the formed part

1.
With the yellow Components button highlighted as shown below, click on the formed part on the graphics
area to highlight it.
2.
Make sure that the N1 N2 N3 option is selected in the Aligning plane: field. If another option is
selected, click the toggle switch and select N1, N2, N3 option from the pull down menu as shown below:
3.
Highlight the displayed formed component by clicking on it once. With N1 highlighted, click on the nodes
of the formed component in an order as shown in the image below. Notice that this region corresponds
approximately to the same nodes of the structural part.
4.
From the Mapping Parameters pull-down list, select the parameter that needs to be mapped, such as
thickness, strain, etc. For this exercise, select Thickness.
5.
Verify that both Model scaling and Result scaling are set to 1.0.
6.
Click Apply.
Step 7: Map and export data

1.
362
From the Templates: pull-down list select the format for export (example: RADIOSS (Bulk Data Format)
and OptiStruct, Nastran, LS-DYNA and Abaqus) as shown below. In this exercise, select Nastran.

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2.
Click the Browse button next to the File name field and specify the name result.dat for exporting.
3.
Click Save.
4.
Click Exec.
A new animation window opens displaying the contours of the mapped result on the structural model.
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363
5.
364
Open the result.dat file using any ASCII text editor. Notice thickness results are mapped as nodal
thickness. This result.dat file can also be included in the model file for further analysis.

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Return to Result Mapping Tutorials
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365

The Die Structure Optimization process is a function used to automatically transfer tool contact forces from
stamping analysis to a structural model and an easy step-by-step setup of die structure optimization model.
The Die Structure Optimization process consists of two steps:
Die Stress analysis
Die Optimization
Tools
Die Stress Analysis and Die Optimization features are under the Applications menu.
Exercise 1: Set up and run Die Stress Analysis

This exercise uses the model file DieStress.hf
Step 1: Launch Die Stress analysis

1.

<installation_directory>\tutorials\mfs\hf\Opti\DieStress.hf
2.
From the Applications drop down menu, select Die Stress Analysis.
The Create/Open Process Instance dialog is displayed, as shown below.
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367
3.
4.
Click Create/Open.
and designate the folder where you want to run the analysis.
The Process Manager tab appears in the tab area. The Process Manager is a step by step approach
to preparing and running Die Stress Analysis.
Step 2: Setup Die Stress Analysis

1.
In the panel area, Steel is shown as the default material in the Material field. Click Apply.
Notice that the white check mark turns green for Tool Material in the Process Manager tab.
Note:
Clicking on Apply at each step will turn the white check mark green in the Process Manager and
a white check appears for the next option.
2.
For the Result file field, select either Radioss or LS-Dyna as the stamping solver.
3.
Click on Browse and locate and load the results of the forming analysis. In this exercise you will use
the file LawnMower2A001.
4.
Click Apply. The Process Manager launches HyperView to query the model and create a list of
components that are available in the stamping model. Once the results are brought back into
HyperForm, you will be able to select which tool to extract the contact forces from.
5.
For the Result part field, select Punch and click Apply. This is the tool from which forces are extracted
at the last step of forming analysis. This will launch HyperView for a moment and will close on itself.
6.
Click on Components: and select the skin of the Die component from the screen. This will be the part
onto which the loads will be mapped.
7.
Click proceed.
8.
Click Apply.
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Step 3: Display only the Punch component

1.
In the Model Browser, click on the plus symbol next to LoadCollector to expand the tree.
2.
Turn off the loads display by clicking on the mesh icon next to operational.
3.
Expand the Components folder, and click on the mesh icon to display the Punch_solid component.
Step 4: Define holding and lifting points on the structural model

1.
Click on the Process Manager tab.
2.
Click on Nodes twice and select By Sets.
3.
Select the Holding component. Notice that the bolt location nodes of the die are highlighted on the
screen.
4.
Click select.
5.
Click proceed.
6.
Click Apply.
7.
Click on Nodes twice and select Lift. Notice the set of nodes on the die gets highlighted on the screen.
8.
Click select.
9.
Click proceed.
10. Click Apply.

11. Enter 1500 in the lifting height: field.
12. Click on Apply. This will create rigid elements connecting the nodes selected on the lifting location of
the punch to the CG of the model as shown below.
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369
13. Click on Apply.

14. Click on Browse and select a location to save the file. Enter the name with a .FEM as the extension.
15. Click on save.
16. Click on Export to produce the input file.
17. Click on Export&Run to produce the input file and run stress analysis.
Note:
Make sure that all the steps on the Process Manager tree has a green tick mark which indicates
that all the steps were successfully completed.
Stress analysis on the punch is done in the background. The results of the stress analysis will be
the input for Die Structure Optimization.
Exercise 2: Set up and run Die Structure Optimization

Die Optimization can be accessed from the Applications menu.
Step 1: Setup the model for optimization

1.
370
Select the Design component under Status column, as shown in the figure below:

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2.
Click on Apply.
3.
Enter 25.0 in the Min Member Size: field.
4.
In the Draw Direction: list, select Z.
5.
Click on Apply.
6.
In the Volume Fraction: field, enter 0.3.
7.
Click on Apply.
8.
For Objective:, select Max Stiffness.
9.
Click on Apply.
10. Next to the Export File: field, click on Browse and enter a file name with the extension .fem.
11. Click on Save.
12. Click on Export to create the input file for optimization.
13. Click on Export&Run to create the input file and run the optimization.
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371

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Altair Engineering Contact Information

Address: ftp.altair.com or ftp2.altair.com or http://ftp.altair.com/ftp

The following countries have distributors for Altair Engineering:

HyperWorks 11.0 Release Notes

Trademark and Registered Trademark Acknowledgments

Manufacturing Solutions 11.0 Tutorials - HyperForm

Manufacturing Solutions 11.0 Tutorials - HyperForm

Manufacturing Solutions 11.0 Tutorials - HyperForm

Radioss One Step Analysis

Manufacturing Solutions 11.0 Tutorials - HyperForm

HF-2005: Basic Addendum Creation Using Die Process

HF-6000: Die Structure Optimization

Manufacturing Solutions 11.0 Tutorials - HyperForm

HF-0010: Introduction to HF Macros

HF-0010: Introduction to HyperBlank Macros

Radioss One Step Analysis

Manufacturing Solutions 11.0 Tutorials - HyperForm

HF-2010: Basic Addendum Creating

HF-6000: Die Structure Optimization

Manufacturing Solutions 11.0 Tutorials - HyperForm

Introduction to HF Macros - HF-0010

HyperForm interface w ith One Step tab active

Manufacturing Solutions 11.0 Tutorials - HyperForm

HyperBlank interface w ith the OneStep tab active

Allows you to import, cleanup, and mesh the model.

Allows you to do post-processing once the analysis is done.

Manufacturing Solutions 11.0 Tutorials - HyperForm

Radioss One Step Utility menu

Incremental process macros

Manufacturing Solutions 11.0 Tutorials - HyperForm

Incremental_Radioss Utility Menu

Manufacturing Solutions 11.0 Tutorials - HyperForm

Form - 1st forming operation setup.

Return to HyperForm Tutorials

Manufacturing Solutions 11.0 Tutorials - HyperForm

Introduction to HyperBlank Macros - HF-0010

HyperBlank interface w ith the OneStep tab active

Allows you to import, cleanup, and mesh the model.

Allows you to setup the model for simulation.

Allows you to do post-processing once the analysis is done.

Manufacturing Solutions 11.0 Tutorials - HyperForm

HyperBlank Utility Menu

Further explanation of each application type is provided in the subsequent tutorials.

Return to HyperForm Tutorials

Manufacturing Solutions 11.0 Tutorials - HyperForm

HF-0100: General Introduction

Using the mouse

Tool bar menu

Toggles and switches

The pull-down menus

Session 2: Using the online help

Manufacturing Solutions 11.0 Tutorials - HyperForm

Session 6: Default HyperForm files

Session 1: Fundamental HyperForm user interface

Manufacturing Solutions 11.0 Tutorials - HyperForm

Die Module: Create and edit binders and addendums

Using the Mouse

Manufacturing Solutions 11.0 Tutorials - HyperForm

input. A two- or three-button mouse can be used with HyperForm.

Performs selection operations.

Right mouse button

De-selects entities in the graphics area. Aborts graphics

Middle mouse button