Dynaform
Uncover Design Flaws with Forming Simulation
Dynaform is a complete die system, LS-DYNA based simulation solution for automotive, electrical, stamping, tool and die industries. It allows organizations to evaluate alternative and unconventional designs and materials, while reducing costs, eliminating prototype tooling, and improving product performance.
By simulating the die system, during the design stage, Dynaform ensures the highest quality formed part and most efficient manufacturing process possible.
Dynaform is a complete die system, LS-DYNA based simulation solution for automotive, electrical, stamping, tool and die industries. It allows organizations to evaluate alternative and unconventional designs and materials, while reducing costs, eliminating prototype tooling, and improving product performance.
By simulating the die system, during the design stage, Dynaform ensures the highest quality formed part and most efficient manufacturing process possible.
Blank Size Engineering (BSE)
The BSE module is used for unfolding 3-dimensional sheet metal parts and estimating blank size, along with blank nesting for maximum material usage, scrap & piece price. BSE can be used to predict thinning, thickening and also to generate a forming limit diagram (FLD).
Key BSE features include:
- Step-by-step Process Wizard
- Simple and Advanced unfolding mode
- Automatic Tipping
- Inner Fill
- Double Attached Parts
- Tailor Welded Blank (TWB)
- MSTEP (Modified One-Step) Solver
- Trimline estimation
- Blank nesting
- Batch BSE
- Batch Nesting
- Blank Development
- Nesting and cost estimation report in HTML and Excel format
- Quick feasibility study
Formability Simulation (FS)
The FS module facilitates the rapid development and validation of single-station, progressive and line die designs. It uncovers hidden problem areas and enables die designers to optimize designs based on accurate forming results.
Key FS features:
- Tree Structure Setup Process
- Simulation Data Manager
- Drawbead Shape and Library
- Drawbead Optimization
- Solid Blank Forming
- Coordinate System Manager
- Instant Section Cut
- Tata Steel FLD
- Springback Prediction
- Automatic Springback Compensation (SCP)
- Multi Stage Simulation
- Progressive Die Simulation
- Line Die Simulation
- Tonnage Prediction
- Face Reflection Analysis
- Stoning Analysis
- Skid Marks
- Special Forming Process
- Sheet Hydroforming
- Roller Hemming
- Superplastic Forming
- Stretch Forming
- Spinning Forming
FS add-ons:
- Blank and Trimline Development
- Hot Forming and Die Structure Cooling (DSC)
- Tube Bending and Forming
Die Evaluation (D-Eval)
Dynaform’s D-Eval module is tailored to analyze CAD based tooling designs during early stage product development cycle. It is equipped with the stamping purpose increment solver which generates reliable formability results in a reasonable response time.
Key D-Eval features:
- Tipping Adjustments
- Binder Generation and Modification
- Surface Morphing
- Die Design Modification
- CAM Trim Evaluation
- Trim Line Check
Die System Analysis (DSA)
The DSA module efficiently predicts most stamping concerns within the stamping production line. DSA consists of three unique capabilities: Die Structure Integrity (DSI), Scrap Shedding/Removal (SSR), and Sheet Metal Transferring/Handling (SMTH).
DSI simulates operational loads to analyze the design integrity of the die. DSI can generate FEA models of the die structure, define operational/stamping loads and evaluate the die structure strength and durability by using implicit and explicit solutions.
The number one cause of stamping line shutdown is the failure of scrap to exit the workstation. This problem can be predicted and corrected in the trim die design stage to avoid troubleshooting in the stamping plant. SHR streamlines model generation for scrap, trim dies, chutes and trim steel. Trimming operations and shedding simulations can be easily setup in the scrap shedding graphic interface.
SMTH simulates the transfer of metal as it progresses through the manufacturing process. It simulates the transfer of the work-piece to the initial die station, movement between stations, pick-up of the finished part and placement on the shipping rack. Part deformation generated in the simulation is used to predict interference between the work-piece and tools. The stress/strain results can be used to prevent damage during transportation, as well as loading and unloading operations.
Dynaform NX Modules
BSE-in-NX
The BSE-in-NX is a complete solution for accurately estimating blank size along with blank nesting for maximum material utilization, minimum scrap and piece costs—all within the familiar NX environment. The solution can quickly produce a blank outline for blank size estimation along with piece price and scrap calculation.
D-Eval-in-NX
The D-Eval-in-NX facilitates engineers to analyze die design within the NX environment using an efficient non-linear finite element program specially developed for simulation of sheet metal forming processes.
CAR BEAM SPRINGBACK ANALYSIS
Project Name: Springback Analysis of a car beam
Industry: Automotive
Baosteel used DYNAFORM in a car beam springback analysis (simulation and real results comparison). Baosteel Technical Center staff claimed that DYNAFORM can accurately predict springback, so as to provide a basis for springback compensation to improve strength, product design and process feasibility.
FORMABILTY ANALYSIS OF CAR PARTS
Project Name: Forming Analysis of Parts of Automobile
Industry: Automotive
Liufeng, Taiwan, is a die factory which simulates car floor parts. Following figure shows the comparison of simulated and the actual results. Liufeng believes that the use of DYNAFORM technology can effectively predict defects in performance and improve the quality of die development and reduce product development cycle.
NATURE AND PROCESS ANALYSIS OF HOME APPLIANCE PARTS
Project Name: Nature and process analysis of home appliance parts
Industry: Home Appliances
CAE analysis using DYNAFORM can accurately predict forming defects and cracking.
SURFACE QUALITY ANALYSIS AND INSPECTION
Project Name: Analysis and surface quality inspection
Industry: Automotive
US DCX related engineers believe that the use of Dynaform software can effectively analyze the surface defects, improve product quality and reduce inspection time.
