TEACHER EDUCATION INSTITUTIONS AND PATHS

Definition of a multiple step process Definition of a multiple step process Definition of a multiple step process

Preparation of tool geometries for the second drawing step Preparation of tool geometries for the second drawing step Preparation of tool geometries for the second drawing step Preparation of tool geometries for the second drawing step The CAD data with the corresponding tool geometry for the second drawing step has to be loaded, checked and divided into die, punch and binder.

Model > Geometry generator > File > Import ... > VDAFS > OK >

in_lesson_08_2.vda > OK > Program: afmesh_3.1 > OK Now the geometry has to be checked for

• free boundaries,

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As there is only a single free boundary, the outline is automatically defined. (Fig. 8.9).

Fig. 8.9 Fig. 8.9 Fig. 8.9 Fig. 8.9

Determination of free boundaries Check for sharp edges

Fillet Fillet Fillet Fillet Check radius: 2.00 > Check > OK

No sharp edges have been found (Fig. 8.10).

Lesson 8: Multiple Step Process and Starting from Restart File Lesson 8: Multiple Step Process and Starting from Restart File Lesson 8: Multiple Step Process and Starting from Restart File Lesson 8: Multiple Step Process and Starting from Restart File

Fig. 8.10

Fig. 8.10 Fig. 8.10 Fig. 8.10

Checks for sharp edges

Check geometry for undercuts:

Tip > geometry is green (Fig. 8.11) which means there are no under-cuts

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Fig. 8.11 Fig. 8.11 Fig. 8.11 Fig. 8.11

Geometry has no undercuts

In the next step the geometry has to be divided into die, punch and binder. Select faces of the binder surface (right mouse button – Shift key) (Fig. 8.12).

Fig. 8.12 Fig. 8.12 Fig. 8.12 Fig. 8.12

Selected faces describe the binder for the second drawing step

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Prepare > Define objects: Binder > Apply

Preparation of the simulation Preparation of the simulation Preparation of the simulation Preparation of the simulation Open Input generator:

Model > Input generator ...

There is already a title predefined (in_lesson_07). Change this to in_lesson_08.

Definition of tools Definition of tools Definition of tools

Definition of tools On the Tools page die, punch and binder of the first drawing step are already defined. Those are grayed out and cannot be modified.

For the second drawing step, the imported and separated tools have to be introduced. Therefore new windows have to be defined on the tools page. First, the die for the second drawing step will be

defined.

Add tool ... > Use settings of tool: punch (first the die has to be defined for the second drawing step, the punch is taken as refer-ence) > Add tool (Fig. 8.13)

Fig. 8.13 Fig. 8.13 Fig. 8.13 Fig. 8.13

Dialog to introduce a new window on the ToolsToolsTools page for die2Tools die2die2die2 The orientation and working direction of the tools are different in the two drawing steps. In the first drawing step the forming was done in a single action process (see Lesson 2). That means that the die and the binder move towards the punch. The punch stays on the press bed.

In the second drawing step the forming should be defined as a dou-ble–action process. The die is fixed to the press bed. Punch and binder are movable (see Lesson 1).

As the specifications are to be done for the second drawing step (die2) it might be reasonable to take all defined values from the punch (drawing direction, etc.). This can be done in the dialog Add tool ... with the option Use settings of tool: punch (Fig. 8.13).

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By doing this, a new subpage appears on the Tools page. All entries for the tool have already been completed correctly.

Only the name and geometry have to be defined.

Name: die2

Geometry > Reference ... > Current geometry: 3 in_lesson_08_2 >

Select objects > Part > Binder > OK (Fig. 8.14)

Fig. 8.14 Fig. 8.14 Fig. 8.14 Fig. 8.14

Window to define geometry of die2die2die2die2

During the preparation of the tool for the second drawing step, the imported geometry had already been divided into die, punch and binder. This division is now used for the definition of die2 as well (Select objects > Part > Binder in Fig. 8.14).

The following is the entry for tool die2 in the Input generator (Fig.

8.15).

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Fig. 8.15

Fig. 8.15 Fig. 8.15 Fig. 8.15

Input for die2die2die2die2

Now the punch for the second drawing step has to be defined. The procedure for this has to be the same as before. As a reference we take the die from the first drawing step (die) and for the definition of the geometry just select the part.

Add tool ... > Use settings of tool: die > Add tool (Fig. 8.16) Fig. 8.16

Fig. 8.16 Fig. 8.16 Fig. 8.16

Dialog for the insertion of a new window on the ToolsToolsToolsTools page for punch2

punch2 punch2 punch2

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Name: punch2

Geometry > Reference ... > Current geometry: 3 in_lesson_08_2 >

Select objects > Part > OK

The initial position of the punch must be entered also (punch2).

This differs from the entries of the reference tool (die). The new def-inition is be done with the command:

Working direction > Move: -100 (Fig. 8.17)

For punch2, this results the following input (Fig. 8.17).

Fig. 8.17 Fig. 8.17 Fig. 8.17 Fig. 8.17

Tools ToolsTools

Tools page – Input for punch2punch2punch2punch2

Finally the binder for the second drawing step has to be defined. As a reference we use punch2, as all entries for punch2 and binder2, (except the name and geometry) should match. When defining the geometry only the binder has to be selected.

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Add tool ... > Use settings of tool: punch2 > Add tool

Tools Tools Tools

Tools Name: binder2

Geometry > Reference ... > Current geometry: 3 in_lesson_08_2 >

Select objects > Binder > OK

The following is the entry for tool binder2 in the Input generator (Fig. 8.18).

Fig. 8.18 Fig. 8.18 Fig. 8.18 Fig. 8.18

Tools Tools Tools

Tools page – Input for binder2binder2binder2binder2

Now a total of six tools have been defined in the Input generator (see Fig. 8.1 – for better illustration the tool of the second drawing step has been moved in the x–direction): The tools for the first step are die, punch and binder (taken from Lesson 7) and for the second drawing step are die2, punch2 and binder2.

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Definition of the Definition of the Definition of the Definition of the Blank

Blank Blank Blank The blank has already been defined for the first drawing step in

Les-son 7. The calculation continues with the partially finished part. No new entries are necessary.

Friction (Lube) Friction (Lube) Friction (Lube) Friction (Lube) Friction can only be defined for the tools of the second drawing step

(Fig. 8.19).

Fig. 8.19 Fig. 8.19 Fig. 8.19 Fig. 8.19

Definition of the friction coefficient for the tools in the second step

Process Process Process Process On the Process page all steps except drawing are grayed out. It is

possible only to modify this page. We define the process (of the tool movement) for the second step instead. In the second step the fol-lowing processes appear:

• Positioning – the part is positioned on a tool for the second process step.

• closing2 – closing of the binder for the second process step

• drawing2 – second drawing step

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Positioning of the

Positioning of the Positioning of the Positioning of the partpart

partpart In order to position the partially finished part on the tool of the sec-ond drawing step, a new step has to be introduced in the Input.

Add process step ... > Positioning > Insert position: Insert after >

drawing > Add process step (Fig. 8.20) Fig. 8.20

Add process: Dialog for positioning the partially completed part In the Input generator on the Process page, a new subpage is added.

The name of the new process step is positioning1. This can be kept as is. This process step describes the transition between the first and the second drawing operation. It can be pictured as if the partially completed part (from the first step) would be taken by hand or by a robot arm out of the first tool set and put onto the second one. Dur-ing the simulation, it is important not to leave out this process step as contact problems during the second step may arise. In this exam-ple, the partially completed part is positioned on die2, as this tool is mounted on the press table.

Sheet positioning > On: die2 (Fig. 8.21)

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Fig. 8.21 Fig. 8.21 Fig. 8.21 Fig. 8.21

Detail ProcessProcessProcessProcess page: Partially completed part is positioned on the second tool set

Now comes the second process step. Binder wrap and drawing pro-cess are defined as separate propro-cess steps (as in reality and also in the previous lessons).

Closing of Add process step ... > Forming > Use settings of forming step: >

drawing > Insert position: Insert after > positioning1 > Add pro-cess step

Process Process Process Process Name: closing2 (Fig. 8.22)

Type: Restrike

Tool control > Show all die: Non-active

punch: Non-active binder: Non-active die2: Stationary punch2: Non-active

binder2: Displcmnt > Velocity: 1 > Set Duration > During time > Time: 100

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Fig. 8.22

Process page: Input for the closing of the binder during the second forming operation

Caution Caution Caution

Caution: In defining the 2^nd operation it is important to select Restrike

Restrike Restrike

Restrike as the drawing type (Fig. 8.22).

Second

tion Add process step ... > Forming > Use settings of forming step:

closing2 > Insert position: Insert after > closing2 > Add process step

Tool control > Show all die: Non-active

punch: Non-active binder: Non-active die2: Stationary

punch2: Displcmnt > Velocity: 1 > Set

binder2: Force > Relative tool: die2 > Const pressure > Value: 20 >

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Set

Duration > During time > Time: 100

Fig. 8.23 Fig. 8.23 Fig. 8.23 Fig. 8.23

Process ProcessProcess

Process page: Input for the 2^nd drawing step Caution

CautionCaution

Caution: In defining the 2^nd operation it is important to select Restrike

RestrikeRestrike

Restrike as the drawing type (Fig. 8.23).

Control Control Control Control WriteRestart > OFF

Job > Start

Lesson 9: Using CAM Tools Lesson 9: Using CAM Tools Lesson 9: Using CAM Tools Lesson 9: Using CAM Tools

2. 9 2. 9

2. 9 2. 9 Lesson 9: Using CAM Tools Lesson 9: Using CAM Tools Lesson 9: Using CAM Tools Lesson 9: Using CAM Tools

In the following lesson we will show an example where the working direction of the tool is not parallel to z–axis (Fig. 9.1).

In these cases the following additional inputs have to be made:

• Definition of working direction of CAM tools

• Special parameters for process definition Fig. 9.1

Fig. 9.1 Fig. 9.1 Fig. 9.1

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