THEORETICAL FRAMEWORK
3.4. TEACHER EDUCATION AND QUALITY UNDER AN INTERNATIONAL AND SUPRANATIONAL PERSPECTIVE AND SUPRANATIONAL PERSPECTIVE
Generate simulation input Generate simulation input Generate simulation input
Model > Input generator ... > Simulation type: Incremental >
Geometry refers to: punch side > OK The title is predefined but it can be changed.
Tools Tools Tools
Tools The definition of tools has to be modified for a hydro–mechanical deep drawing process. The die consists only of a flat binder ring with a die radius and a vertical wall down.
Proceed as follows. First, delete the defined die geometry using:
Input generator > Tools > die > Geometry > Delete data > Delete Now define the die using:
Input generator > Tools > die > Geometry > Reference … > Pick faces > Activate all (Fig. 11.4)
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
Fig. 11.4 Fig. 11.4 Fig. 11.4 Fig. 11.4
Menu: Reference tool geometryReference tool geometryReference tool geometryReference tool geometry with activated option Pick facesPick facesPick facesPick faces Select faces of the punch, binder radius and punch radius (Fig. 11.5).
Fig. 11.5 Fig. 11.5 Fig. 11.5 Fig. 11.5
Geometry with selected punch faces, binder radius and punch radius
Deactivate faces using
Reference tools geometry > Deactivate Define die using
Reference tools geometry > OK
Geometry of the die is displayed in Fig. 11.6.
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
Fig. 11.6Fig. 11.6 Fig. 11.6 Fig. 11.6
Geometry of die
The definition of the punch has already been done and there is no need to change this.
Columns for the binder has to be defined. It is recommended to use Tool center
Blank Blank Blank
Blank The blank outline has been generated in CAD and can be imported.
Use:
Blank > Import > IGES > Use all > Rotate > OK (Fig. 11.7) Fig. 11.7
Fig. 11.7 Fig. 11.7 Fig. 11.7
Dialog: Import line(s)Import line(s)Import line(s)Import line(s)
in_lesson_11_crv.igs > OK > Program: afmesh_3.1 > OK
File in_lesson_11_crv.igs contains all curves that define the blank outline. Select three curves Curve 1, Curve 2 and Curve 3 in the menu Select curve and confirm with OK (Fig. 11.8).
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
Fig. 11.8 Fig. 11.8 Fig. 11.8 Fig. 11.8
Dialog: Select curveSelect curveSelect curveSelect curve with selected curves Curve 1Curve 1Curve 1, Curve 2Curve 1 Curve 2Curve 2Curve 2 and Curve 3
Curve 3Curve 3 Curve 3
Define two symmetry lines:
Input generator > Blank > Add symmetry … > Click segment Select the horizontal part of the blank boundary and confirm with OK.
Repeat for the vertical part of the blank boundary:
Input generator > Blank > Add symmetry … > Click segment
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
Select vertical part of the blank boundary and confirm with OK (Fig. 11.9 and Fig. 11.10).Fig. 11.9 Fig. 11.9 Fig. 11.9 Fig. 11.9
Blank Blank Blank
Blank page of Input generator
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
Fig. 11.10 Fig. 11.10 Fig. 11.10 Fig. 11.10
Blank boundary with two symmetry lines
Process Process Process Process A double action process is already defined on the Process page.
This means that first the binder closes and then the punch moves until bottom down. Duration of the process steps depends on the tool position (Move on Tools page). This has already been defined for this example.
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
Fig. 11.11Fig. 11.11 Fig. 11.11 Fig. 11.11
Process Process Process
Process page of Input generator Input for Gravity (Fig. 11.12):
Process > gravity > Gravity: downwards > die: Stationary
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
Fig. 11.12 Fig. 11.12 Fig. 11.12 Fig. 11.12
Process ProcessProcess
Process page of Input generator – subpage gravitygravitygravitygravity
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
Process step binderwrap (closing) is already defined (Fig. 11.13).Fig. 11.13 Fig. 11.13 Fig. 11.13 Fig. 11.13
Process Process Process
Process page of Input generator – subpage closingclosingclosingclosing
In the active hydro–mech process, the blank will be preformed into the binder opening due to increasing pressure of the fluid from below the sheet. The sheet thus gets a uniform strain distribution.
Therefore a new process step has to be inserted after the process step closing:
Add process step ... > Forming > Use default setting of forming step: > drawing > Insert position > Insert after > closing > Add pro-cess step
A new process step is added. Now change the process step type to Hydro mech.
Process step > Type: Hydro mech
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
On the right side of this option a selection of different fluid–based forming options appears (Fig. 11.14).
Fig. 11.14 Fig. 11.14 Fig. 11.14 Fig. 11.14 Menu to define a fluid based forming step
• Type: Hydro mech, switches to fluid based forming pro-cess´.
• Passive: Pressure increase is due to punch movement and volume reduction.
• Active pressure: Pressure increase is controlled by valves.
• Active volume: similar to Active pressure, but volume change is defined.
• Active height: similar to Active pressure, but dome height is defined.
Define the pre–forming step with a dome height of 20mm and change the binder pressure to 20 N/mm² to avoid any draw–in of the material.
Name: pre_forming > Type: Hydro mech > Active height
Tools > die: Stationary > punch: Non-active > Binder > Force > Rel-ative tool: die > Const pressure > Value: 20 > Set > Hydro mech: >
Delta h: 20 > Below
The fsluid pressure comes from the negative z–direction (Fig. 11.15).
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
Fig. 11.15Fig. 11.15 Fig. 11.15 Fig. 11.15
Added process step for pre–forming of active hydro mech
No real die exists for hydro mechanical deep drawing. The blank is clamped between the force–controlled binder and the die ring, the punch deforms the sheet and from below the sheet an active pres-sure acts. This prespres-sure presses the sheet against the punch and the desired geometry can be formed. This has to be defined in the Input.
Define process step type Hydro mech for process step drawing. It should be defined as active hydro mech. The pressure should be controlled to 0.8 N/mm² during the first 475 mm punch stroke and then increasing linearly to 5 N/mm² until bottom down (500 mm punch stroke). Binder pressure should be 2 N/mm² to allow mate-rial flow.
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
Proceed as follows:
Name: drawing > Type: Hydro mech > Active pressure
Tools > die: Stationary > punch > Displacement > Velocity: 1 >
Binder > Force > Relative tool: die > Const pressure > Value: 2 > Set Hydro mech: Active pressure > Time variable > From start > Time:
0, 475, 500 > Pressure: 0.8, 0.8, 5 > Set (Fig. 11.16)
Fig. 11.16 Fig. 11.16 Fig. 11.16 Fig. 11.16
Menu: Active pressureActive pressureActive pressureActive pressure with specified pressure
• End p: End pressure in N/mm²
• Time variable: Pressure depending on process time
• From Start: Time is measured from process start.
• From End: Time is measured from process end.
• At End: Last specified time is moved to process end.
Define the lower side of the sheet as side where the fluid pressure acts.
Hydro mech > Below (Fig. 11.17)
Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing Lesson 11: Hydromechanical Deep Drawing
Fig. 11.17Fig. 11.17 Fig. 11.17 Fig. 11.17
Process Process Process
Process page of Input generator – page drawingdrawingdrawingdrawing Definition of all necessary input option is completed.
Start the Simulation Start the Simulation Start the Simulation Start the Simulation Job > Start simulation ...
Close AutoForm–User Interface Close AutoForm–User Interface Close AutoForm–User Interface Close AutoForm–User Interface
The user interface can be closed with following option:
File > Quit or hotkey Ctrl – Q.