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Springback R7 Update
Advanced Training
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2
 Training Content
• Springback Simulation • AutoForm-Compensator
• Check List • Workflow of Springback Compensation
• Simulation Setup • Different Regions for Springback Compensation
• Reference Geometry • Compensator Functionality
• Export of the Compensation
• Clamping Concept Definition • Springback Compensation and Symmetry
• Real Measurement • Smoothing Control
• Constrained Springback • Springback Compensation and Scaling
• Fixed Boundary Condition
• Drawshell Mode
• Optimized Part Fixture

• Die Face Use Case

• Compensation at an Early Stage

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Springback Simulation
Checklist
Simulation Setup
Free Springback
Reference Geometry
 Check List
• Final Validation (FV) Settings
• Tools
• Tool penetrations (Kinematic Check)
• Meshing (8 elements over a 90° radius)
• Punch support
• Import geometry in vehicle coordinate system and tipping in AutoForm
• Blank
• Shape, position, sheet thickness, material data and rolling direction
• Drawbeads
• Use of Adaptive Line Bead model in combination with Flattening
• This model can also be combined with Unflattening.
• Lubrication
• Steel: µ = 0.15
• Aluminum: µ = 0.13 (dry lubricant)
µ = 0.15 (basic lubricant)
Before starting the springback simulation review
• Convergence Behavior all settings with a Check List!
• Warnings ...

5
 OP Setup and Solver Settings
• Application of the Final Validation settings (Engineering Phase: FV)

• Considering binder closing for Cutting with Tools

• Calculation of free springback after each operation (Free Springback at End of Operation)

• Scaling of the draw stage, if necessary (Scaling of Tools)

• Activate the option Locating/Gravity at Begin of Operation.

• Support Type: Binder

• Force controlled: Spring Controlled

• Distanced: Gap Controlled

6
 Binder
Consideration of the Spotting State
• Depending on the defined value for Tool Ktool = 10 : p ≈ uniform, fully adapted
Stiffness the thinning of the sheet is
automatically applied to the tool surfaces. Ktool = 50 : p = distributed, partially adapted
• If the value for the result variable Blankholder
Pressure is greater than zero, the tool is Ktool = 1000 : p = spotted, no adaption
assumed to be fully adapted.

F
Binder

t<t0 Sheet t>t0

Die

7
 Drawbeads
• Use of the Adaptive Line Bead model and
Flattening for the simulation of the drawbead.
Die
If necessary, the option Unflattening can be used.
Line model

• Segmented Binder

• Only the area between the drawbead and the punch

opening is spotted.
• Partial Bearing to only apply the binder pressure to
the inner area of the binder. Boundary of the
Force controlled Bearing Area
binder
F
No-Bearing Area Bearing Area
no binder pressure binder pressure

8
 Geometrical Drawbeads
• If the drawbead geometry is available in CAD, it can be used for the forming simulation.

• The entire binder is defined as Spring Controlled.

• All milled recesses have to be considered in the geometry:

• Radii in the groove and the bead
• Possibly outer binder area with gap

• Advantage
• 3D effects are taken into account
• Definition of the Line Bead model is not necessary

• Disadvantage
• Significantly more computation time
• Time-consuming modification of the drawbead

9
 Free Springback

• Free Springback is used, if no clamping points are known.

• The part position and tipping is adjusted using the Best Fit algorithm.

• Gravity is never taken into account for free springback.

• Calculation of Free Springback

• Production: Add Measuring OP
• Process stage: Free Springback

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Clamping Concept Definition

Real Measurement
Constrained Springback
Fixed Boundary Condition
 Real Measurement
• The part can be placed on Tools (imported geometry) or
Spheres Groups (hemispheres).

• Sphere Groups exactly act as Tools, with the exception that

the geometry is generated in AutoForm.

• During Real Measurement the Pilots have surface contact

and normal contact (behave as Guides during drawing).

• The diameter of the Pilot has to be 0.2 mm than the hole

diameter.

• During Real Measurement gravity is always taken into

account.

12
 Real Measurement
• You have to specify on which side of the sheet the tool is placed (Upper Side or Lower Side).
• The definition of the tool side is realized during blank insertion.
If the part is rotated, you have to specify Upper Side.
• If no Pilots have been defined, the part must be stabilized.

Mit Pilot Ohne Pilot

Das Bauteil wird stabilisiert.

Das Bauteil hängt am Pilot.

Bauteile liegen auf einer schiefen Ebene.

13
 Sphere Group Definition
• Definition of Spheres

• Contact side of the sheet

• Contact point
• Direction (Axis: defined by Rotation and Incline)
• Radius

• Spheres are acting as Tools.

Contact
Sheet Point

Sphere Sphere
Axis
r

14
 Definition Pilots 1/3
• Pilots pull the boundary of the formed sheet and fix it.
• A displacement parallel to the boundary is allowed.
• The force at the Pilot is acting radially to the Pilot axis.

Not sprung back geometry

Sprung back geometry

15
 Definition Pilots 2/3
Pilots pull the boundary of the part: Pilots only have edge contact:

Part before springback

Before springback

16
 Definition Pilots 2/3
Pilots pull the boundary of the part: Pilots only have edge contact:

Part after springback

After springback

17
 Definition Pilots 3/3
• The Pilots are acting at their outer diameter, i.e. they may not be positioned exactly at the part boundary, but
have to be displaced by the amount of the radius.

• The diameter should be ca. 0.2 mm smaller than the diameter of the hole.

• In reality the parts are supported at the locating holes. It must be checked, whether the clamping can be
represented more realistically by an additional tool.

• Pilots are not suited to hang up the part, e.g. to hang a side wall in vehicle orientation at two Pilots.

18
 Pilots: Real Measurement – Constrained Springback
Real Measurement Constrained Springback

Edge contact

Contact to the sheet plane

Can only apply compressive stress

to the sheet boundary

The part can be hung up at a

single Pilot. with Version R6

19
 Real Measurement – Clamps
The springback calculation is realized in two steps:
1. Springback Process Step: 2. Springback Process Step:
Clamps open Clamps closed

Clamping

20
 Real Measurement – Clamps
• Support:
• Supporting Above / Below:
Clamp is taken into account in opened state
(Clamp 1_1 and Clamp 2_1).

• Non-Supporting Above / Below:

Clamp is only taken into account in closed state
(Clamp 3_1 and Clamp 4_1).

21
 Real Measurement – Clamps
• Action:
• Close: Clamp is closed in the second step
(Clamp 1_1 und Clamp 3_1).

• Keep Open: Clamp remains open (Clamp 2_2).

• Deactivate: Clamp is not taken into account for

the first and second step.

22
 Real Measurement
• Definition of Above / Below

Below Above

Before closing the

• The Clamp geometries refer to the same side of
the initial blank as the tool geometries.
t0
• If the tools do not have an offset (on the PL Ref

clamps
page), an additional reference side for Real
Measurement has to be defined on the Process

Keep open
stage.

t0
• The side of the sheet (Above / Below) on which

After closing the

the Clamps are acting can be selected Ref
independently of the reference side of the
coordinates.

Close

clamps
t0
Ref

23
 Constrained Springback 1/2
• Definition of the clamping and fixing concept as in version AutoFormplus R3

• Optional application of Clamps and Pilots

24
 Constrained Springback 2/2
• The definition of the Pilots is different as
for Real Measurement.

• If an offsetted draw die is used, the position of

reference side has to be specified. Otherwise the
Tool Offset definition of the PL page is used.

• The Clamps can act double-sided or single-sided.

You can specify, whether the Clamp is acting on the
upper or lower side.

• Use Symmetry (single and global),

if a Symmetry plane has been defined.

25
 Definition Clamps
• At the Clamps the formed sheet is pulled in normal direction and fixed.
• A displacement in the plane is allowed.

Clamps normal
to the flange

Tangential displacement
is allowed (without friction).

26
 Clamp One/Double Sided Above/Below
Double Sided
Above One Sided Above

Double Sided Below

One Sided Below

Double Sided Above: Double Sided Below:

Flexible side
Thinned and sprung Fixed side
back sheet Thinned and sprung
back sheet
Initial
Initial Sheet thicknes
Sheet thickness

Fixed side
Flexible side
27
 Clamp One/Double Sided Above/Below
Double Sided
Above One Sided Above

Double Sided Below

One Sided Below

Double Sided Above: Double Sided Below:

Fixed side above

Fixed side below

28
Exercise 1:

Door Inner – Real Measurement

 Exercise 1: Door Inner – Real Measurement
• Calculate the springback of the Door Inner taking into account the clamping concept in vehicle orientation.
• The coordinates of the Pilots are available in the file Pilot.igs.
• Project the coordinates of the Clamps onto the geometry.

• The part can be hung up with horizontal

Pilots for Real Measurement and
Constrained Springback.

• It is important that the part is very

precisely positioned at the Pilots before
the Locating process step.

• Horizontal Pilots should be preferred

(parallel to the xy plane).
• If the Pilots are not horizontal,
Clamps or Tools should be used.

Use Restart option!

30
 Real Measurement
• Restart after F-70

• Import the coordinates of the Pilots

CoordPilots.igs

31
 Plan Tipping M-100
• Tip the operation M-100 into vehicle orientation.

• Delete Free Springback.

• Un the Product Coordinates view all geometries

are positioned in the orientation.

32
 Plan Introducing reference geometry
• Tip the operation M-100 into vehicle orientation.

• Delete Free Springback.

• Un the Product Coordinates view all geometries

are positioned in the orientation.

33
 M-100 Constraints Real Measurement
1 1• Select Real Measurement

2• Add a Pilot Group

2 3• Copy From… CoordPilots

4• Edit…: Delete the Pilot in the circular hole

5• Switch off Use Symmetry

3 4 •6 Rotation = 90.00° and Incline = 0.00°

5
7• Diameter = 18.0 mm (Take into account the sheet
thickness!)

34
 M-100 Constraints Additional Pilot Group

1• Add an additional Pilot Group

2 3

4 2• Copy From…: CoordPilots

1 3• Edit…: Delete the Pilot in the slot

5
4• Switch off Use Symmetry

6 5• Rotation = 90.00° and Incline = 0.00°

•6 Diameter = 24.00 mm

35
 M-100 Constraints Add Clamps

1• Switch off Use Symmetry

4 2• Add Clamps: Set four points on the door frame.

3
3• Support: Supporting Below

4• Simultaneously

1
• Save and start the simulation:

36
 Displacement in Normal Dir
• Display the Min and Max values for the result variable Displacement in Normal Dir.

37
Exercise 2:

Reinforcement – Constrained Springback

 Exercise 2: Reinforcement – Constrained Springback
• Open the simulation Reinforcement_FV.afd and define Constrained Springback.
• The coordinates of the Pilots und Clamps are available in the files Pilots.igs and Clamps.igs.

Use the Restart option!

39
 M-50 Constraints Constrained Springback
1• Make a Restart after operation F-40.

Import

2• Import the coordinates of the Clamps and Pilots

1
(Clamps.igs and Pilots.igs).

3• Delete Free Springback and

4
4• define Constrained Springback.

40
 M-50 Constraints Pilot Group

1 1• Add a Pilot Group.

2• Select the previously imported coordinates Pilot.

3• The part is a double attached part. For springback

calculation only one part is taken into account.
Thus, switch off the option Use Symmetry.

3 4• The Pilot diameter is to be 0.2 mm smaller than

the hole diameter. Change the Pilot diameter to
15.8 mm.

41
 M-50 Constraints Clamps

1• Add the Clamps using Copy From.

Select the previously imported points Clamps.

2• The „fixed“ side of the Clamp refers to the lower

side of the sheet (blue side). Define the support
type Double-Sided Below for all Clamps.

3• Switch off the option Use Symmetry.

1

Start

2 4• Start the springback simulation:

42
 M-50 Springback Springback Evaluation

3 •1 Evaluate springback.

•2 Near by the Clamps the springback is to equal zero.

The following reasons might result in deviations:
1 • The results are represented per element. The
average value of three nodes is determined.
• Thinning is taken into account. During closing
of the clamps the sheet can be displacement
by the amount of thinning.

•3 As no reference geometry has so far been defined,

the result variable Distance from Reference cannot
be indicated.
2

43
 M-50 Reference Add Reference Geometry

1 1• Add a reference geometry.

2• Define the geometry Reinforcement_Part as reference

2
geometry.
3
3• The part is measured from the gray side (upper side). Select
Adjustment Side Upper Side of Blank.

4• Save the afd file.

As the definition of the reference geometry does not influence
the simulation result, the simulation results are not deleted.

44
 M-50 Springback Distance from Reference

1• Evaluate the distance to the reference geometry.

1 The Distance from Reference result also contains the

thinning of the sheet.

2
2• The resulting forces and the displacement of the Clamps
are indicated on the Results page.

3
3• The forces in x, y and z direction are indicated in the solver
log.

45
 M-50 Springback Evaluation of the Force at Clamps and Pilots
• The clamping force (Normal Force) and the part
displacement (Normal Displacement) are indicated
under Results.
• If the sheet lifts up at a one-sided Clamp, the Normal
Displacement is < 0.
• Limits can be defined for the force and the
displacement. If these limits are exceeded, the
Clamps are colored red.
• The forces and displacements for Clamps and Pilots
in x, y and z direction are indicated in the solver log.

46
 Definition Above and Below

The definition of Above and Below is realized during blank insertion.

If the part is rotated, the one-sided Clamps and the fixed side of the double-sided Clamp are placed on the
upper side (Above).

47
Exercise 3:

Hood Outer – Fixed Boundary Condition

 Exercise 3: Hood Outer – Fixed Boundary Condition
• Compare the springback of the simulation HoodOuter.afd after trimming (T-40) and the flanging (F-50).
• Use the Fixed Boundary Condition to make sure that the part is located in the same position.

Rotate the part by 180° Rotate the part by 6°

D-20 Double Action Draw T-30 Trim T-40 Trim F-50 Form

Use the Restart option!

49
 M-45 Constraints Fixed Boundary Condition
• Import the points HoodOuter_FBC.igs: The *.afd
file can be stored subsequently. The results remain
unchanged.

• Restart after T-40

• Skip OP of F-50 and M-60

• Delete Free Springback

• Create the Fixed Boundary Condition

50
 M-45 Constraints Fixed Boundary Condition

1• Copy From HoodOuter_FBC

1 2 2• Use Symmetry off

3• Lock the degrees of freedom using the 3-2-1 rule.

• Start the simulation:

51
 M-60 Constraints Fixed Boundary Condition
1 • Springback calculation with FBC in M-60

• Make a Restart after F-50 in the base simulation

HoodOuter.afd.

• Delete Free Springback in M-60.

3
1• Select Fixed Boundary Condition.

2• Copy coordinates HoodOuter_FBC.

2 4 3 4• Lock the degrees of freedom and switch off Use

Symmetry.

• Start the simulation:

52
 M-45/60 Springback Displacement in Normal Dir

Springback M-45

Springback M-60

53
 Springback – Symmetry
• A symmetry plane represents also a clamping for the springback calculation.

Displacement in
x x direction is locked.

Rotation about the

y axis is locked.

54
 Summary: Constrained Springback

• Gravity is taken into account for Constrained Springback. Beginning with version R6 you can switch off gravity
calculation.

• Whether the coordinate of the Clamp refers to the upper or lower side, is specified on the PL page.

• When using a draw die with an offset, the position of the reference side has to be specified.

• One Sided Above / Below specifies, on which side the one-sided Clamp is placed.

• Double-Sided Above / Below specifies the “fixed side” of the Clamp (difference: thinning).

• Upper and lower side are determined during blank definition.

• In the simulation the surface of the formed sheet is pulled by the Clamp, i.e. if the position of any Clamp has
not been correctly defined, the formed sheet is displaced to original position and the clamping is wrong!

55
 Fixed Boundary Condition

• The Fixed Boundary Condition (FBC) allows to reset the some degrees of freedom of a sheet node to zero for
the springback calculation.

• This is the displacement in global x, y and z direction.

• Gravity is taken into account. But you can deactivate the gravity calculation.

• To determine the part kinematically at least three nodes and six degrees of freedom have to be reset to zero.
Each of the three main directions has to be specified at three nodes (e.g. ZZZ,YY,X).

• The coordinates are specified and the neighboring node is used.

56
 Application Fields of the Fixed Boundary Condition

• Defined position of the sprung back part (e.g. comparison of simulation results)

• Clamping concept for springback compensation

• No kinematically determined mounting of Clamps and Pilots possible (e.g. no holes for Pilots)

• Determination of the clamping concept

• For the comparison of the measuring report to the simulation Real Measurement has to be used.

Surface of the sphere

The part has been displaced.

57
Exercise 4:

Hood Outer – Symmetry

 Exercise 4: Hood Outer – Symmetry
• The simulation HoodOuter_Sym.afd has been calculated with a half blank.
• Define a minimal clamping concept using the Fixed Boundary Condition.

59
 M-50 Constraints Fixed Boundary Condition

• Import the coordinates of HoodOuter_FBC.igs

• Make Restart from End of F-50

• Delete Free Springback

• Select Fixed Boundary Condition

• Copy the coordinates HoodOuter_FBC.

• Lock as few degrees of freedom as possible.

• Start the simulation:

In the Product
Coordinates view part
and blank are positioned
one above the other.

60
 Relocatability

FBC relocatable FBC not relocatable

61
 Difference between Clamps and FBC (1/2)
• Clamps: Constraints normal to the sheet plane (Pilots to boundary)
• Similar to the real clamping concept

• FBC: The degrees of freedom (x, y, z displacement)

of a node are set to zero.

62
 Difference between Clamps and FBC (1/2)
• FBC: The nearest node is searched. If the distance is too great, the FBC is not taken into account.

For the Clamp the part is displaced or deformed for an

overdetermined support.

The coordinates are not positioned on the sheet

or on the reference geometry:

63
 Summary: Fixed Boundary Condition
• The Fixed Boundary Condition (FBC) makes it possible to lock individual degrees of freedom for springback
calculation.

• Gravity is not taken into account for Fixed Boundary Condition.

• A symmetry plane is also a boundary condition for springback calculation.

• If the FBC is not positioned on the part, the nearest node is searched.

• Contrary to Clamps the part is not displaced or deformed.

• Contrary to Adjustment a statically overdetermined clamping can be provoked.

• For the comparison of the measuring report to the simulation Real Measurement is to be applied.

64
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Compensator
Springback Compensation Process
Different Regions for the Springback Compensation
Compensator Functionality
Export of the Compensation
Springback Compensation and Symmetry
Smoothing Control
Springback Compensation and Scaling
 Springback Compensation Process
Active surfaces in
Fix Draft
CAD quality

Simulation with
Compensation of
Springback
the Tools

Distance of the sprung back part to

the reference geometry Compensation
strategy
Direct

Deviation Transition
from
Tolerance

Export of the compensated

active surfaces or vector field

66
 AutoForm-Compensator

Reference Design File

clone clone clone

Comp. Strategy 1 Comp. Strategy 2 Comp. Strategy 3

Iteration 1 Iteration 1 Iteration 1

Comp. Strategy 1 Comp. Strategy 2

Iteration 2 Iteration 2

Compensated Compensated
---------------------
Tools Tools

• During cloning the springback results are stored in a new afd file.
• Each M-OP is available for compensation in the cloned file.
• The Compensator can be applied for Tool Import or Part Import.
• Recommendation: Only use a single set of tool surfaces per operation
• All additional geometries on the Import page of the Part stage are available for compensation (also not used geometries).

67
 AutoForm-Compensator
1 1 Combination with other modules of the Modify page

2 Use different M-OP for different tool geometries in the first

iteration.

3 Set Dependent… for compensation definition: Define

compensation region of a tool geometry. The dependent tool
geometry will be compensated with the same vector field.
2
4 Copy Regions…: Define compensation region of a tool geometry
and copy the regions definition to another tool geometry.
Afterwards the copied regions can be edited.
3 4
5 Convert to…: Select an existing region and change the type, e. g.
change from Fixed to Fix Draft.

5 6 Preview function for compensation: For example to check zebra

lines or backdraft after compensation

68
 AutoForm-Compensator
• Combination with other Modules of the Modify Page

• E. g. add Radius if the die radius is destroyed due to compensation.

• Check tool definition on Process stage afterwards.

69
 Regions
• 4 different regions:
Plane binder
• Direct
Direct
• Fixed
Fixed
• Fix Draft

• Transition
Flanging up from working direction

Fix Draft
Curved binder

70
 Regions: Direct, Fixed
• Direct • Fixed

• Is represented in orange color • Is represented in blue color

• Reversion of the node displacement • All Fixed surface keep their original shape

• Reversion dependent of the Compensation factor • If the Fixed region is inserted into one of the
following iterations, the surfaces (even if they
have already been compensated) are reset to their
• Smoothing Control for smoothing the
original state.
compensation

71
 Regions: Fix Draft
• Fix Draft

• Is represented in purple color

• Definition of a Reference Curve and a Working Direction

• Along the Reference Curve sections are defined in working direction.

• Compensation along the Reference Curve is applied to the section.

• The compensation result for Fix Draft is controlled by the following parameters:
• Compensation Factor
• Smoothing Control
• Working direction

72
 Fix Draft – Flanging up in Working Direction
Sprung back part:

Reference Curve

Sprung back
part

Compensation regions:

Fix Draft
Compensated
tool

Direct Original tool

73
 Fix Draft – Binder Surface
Sprung back part Compensation regions

Sprung back part

Compensated tool
Original tool

Reference Curve

74
 Regions: Transition
• Transition

• Is represented in green color

• Required to separate different regions

• Tangential with respect to the neighboring region

• Check / Automatic Check

Check

• Is predefined in each strategy.

75
Exercise 5:

Hood Inner
 Exercise 5: Hood Inner
• Main Focus

• Influence of Gravity
• Compensator Functionality
• Dual View
• Convert Region

77
 M-50 OP Setup Switch off Gravity

• Simple option for the determination of gravity (e.g. for the minimal clamping concept)

• Open the simulation Hoodiner_Full.

• Make a Restart after operation T-40.

• Switch off gravity on the page

OP Setup M-50.

• … and start the simulation.

78
 Displacement in Normal Dir
No Gravity Gravity

The influence of gravity amounts to ca. 2 mm.

Take care that the option No Gravity is switched off for the compensation.

79
 Clone for SB-Comp…
• Open the simulation: Hood_inner.afd

• Start the springback compensation:

Clone for SB-Comp…

80
 Compensation Strategy
• Clone: Generation of a new design file
Compensate entry on the Modify page
(see Die Face use case).

• Compensation strategy: Compensate D-20 with

the springback result M-50.

81
 Modify Assign Regions
• Hoodinner D-20: Activate

• Initial Measuring operation: M-50

82
 Assign Regions
• Define regions
• Binder: Fixed
• Addendum: Transition
• Part: Direct
• Start the compensation using Apply
Compensated
• Dual View – Dynamic Section

Original

83
 Convert to Fix Draft
• Define Regions
• Convert the binder area to Fix Draft

Reference curve
(Direct Boundary Curve)
And start the simulation.

Compensated

Reference curve
Original

84
 Distance in Normal Dir
Base 1. Iteration 2. Iteration

85
 Consideration of the Compensation Factor
Example: Drawing and springback, compensation of the draw die with a factor.

Calculation of springback compensation ci:

ci = ci-1 - ai ( si-1 + ci-1)

with:
ci : Compensation in the ith iteration
si : Springback result (Material Displacement of the ith iteration)
ai : Compensation factor of the ith iteration

Example: a = 0.5 a = 1.0

c1 = - a s0 = - 0.5 s0 c1 = - a s0 = - 1 s0
c2 = c1 - a (s1 + c1) c2 = c1 - a (s1 + c1)
= 0.5 c1 – 0.5 s1 = - 1.0 s1
c3 = c2 - a (s2 + c2) c3 = c2 - a (s2 + c2)
= 0.5 c2 – 0.5 s2 = - 1.0 s2
… …

86
 Compensation with a Compensation Factor of 0.5
Original tool 1. Iteration

Originalwerkzeug

s0
s1
c1 c2

Compensated tool Tool after the second iteration

s0 : Material Displacement

c1 = - 0,5 s0 c2 = 0,5 c1 – 0,5 s1 c3 = 0,5 c2 – 0,5 s2 c4 = 0,5 c3 – 0,5 s3

…
The springback compensation also converges with a compensation factor of 0.5!

You can freeze the current iteration with a compensation factor of 0.

87
 Example: Compensation Factor

1.438 -0.31 0.159

0.918

88
 Export
• Different formats are available for the export of the compensation results:

• IGES format

• AF (Compensation vector field in two files)

• STL (Compensation vector field in two files)

• TXT (Compensation vector field in one file)

89
 Smoothing Control
• Background Information
• New tool surfaces have to be calculated for compensation.
• This calculation is based on a complex mathematical function.

• Smoothing Control controls the complexity of the mathematical approach for this function.

• 0  low complexity  smooth compensation

• 1  high complexity  accurate compensation

90
 Smoothing Control
• Effect of Smooth and Accurate

• Initial geometry

• Springback

• Compensation
Smooth Accurate

91
 Smoothing Control
• Handling / Recommendation:

• Low Control Value

• Rippling tendencies in large surface are smoothed.
• Small structures remain unchanged, but the springback tendencies are smoothed.

• High Control Value

• Suited to represent local effects accurate

• Calculate
• Average and maximal deviation

• Different local smoothings can be represented by different Direct Regions.

92
 Scaling 1/2
• Scaling of tools on the Process Stage

• Volumetric scaling
• Is defined separately for an OP
• Define Scaling Value
• Define Scaling Center
• Die The scaling can influence the results!!!

• Recommendation

• Import the unscaled geometry

• Scaling of the draw stage on the Process stage

93
 Scaling 2/2

• The exported vector field contains no scaling of the tools.

• If a scaling is defined on the Process stage, this has to be realized for the preparation of the CAD data.

• Attention! In version R5.2 and beyond no scaling of the compensated data (IGES surfaces and vector field) was
required in CAD.

94
Exercise 6:

Cap Profile
 Exercise 6: Cap Profile
• Main Focus

• Compensation with different Measuring operations

M-60

M-45

M-35

M-25

96
 Clone for SB-Comp…
• Open the simulation: Cap_Profile_Base.afd

• Start the springback compensation:

Clone for SB-Comp…

• Compensation of D-20 with M-60

and F-40 with M-45

M-60

M-45

M-35

M-25

97
 Modify Assign Regions
Assignment of regions D20_Die

Assignment of regions F40_Post

98
 Distance in Normal Dir
Base

1. Iteration

2. Iteration

99
Drawshell Approach
 Drawshell: Approach
• Drawshell
• The shape of the part after springback matches the shape of the tools of the following OP.
• This avoids undesired plastic deformation during closing.
• Might be necessary for some outer panels.
• Example:
• Springback

• Standard Compensation

• Drawshell

• Part before springback Part after springback Original tool shape Tool after ompensation

101
 Drawshell: Requirements
• Compensation Factor = -1
• Refer to the springback result before Drawshell operation

• Basic Process

D-20 M-25 T-30 … … M-XX

Compensation Factor = -1

Compensation Factor = 1

• Compensation of D-20 changes the springback result of M-25!!!

D-20 (compensated) M-25 (new)

102
 Drawshell: Workflow
• After the compensation of the drawing operation the springback result after drawing changes.
• Therefore the Drawshell method cannot be performed within one iteration.

1. Iteration
• Compensation of the drawing operation
• Skip OP after M-25
• Start simulation

2. Iteration
• Compensate T-30 with M-25 (Drawshell Mode)
• Lock D-20
• Deactivate Skip OP
• Start simulation

Repeat the 1. and 2. iteration until the compensation converges.

103
Exercise 7:

Hood Inner – Drawshell

 Exercise 7: Hood Inner – Part 1

• Compensate the part Hood Inner as follows: D-20

• Compensate the draw die D-20 with the

springback result M-50.

• Compensate the first trim operation T-30 with the T-30

springback result after D-20 as Drawshell.

• Check the trim angles after springback

compensation.
T-40
• Use the Restart option for compensation.

• You can realize the springback compensation for

the half part Hoodinner_Half.afd to reduce the
solver times (Single simulation: 8 Cores 12 min vs.
M-50
36 min).

105
 Modify Clone for SB-Comp…
• Compensation of the Draw Die • Compensation of the geometry Hoodinner D-20
with the springback result from M-50:

• The simulation cannot be set up at a Restart point.

Use Clone to realize the first compensation:

106
 Modify Compensation Regions for D-20
• Assignment of the compensation regions as shown below

• Use the Boundary Curve of the Direct region as Reference Curve for
the Fix Draft region
• Start the springback compensation by clicking Apply.

During the calculation of

the springback results it
is possible to work on
other design files.

107
 Production Skip Operations
• First Iteration • Start the simulation.

• Skip all operations after D-20.

• Update the drawbeads:

108
 Modify Clone for SB-Comp…
• First Iteration • Hoodinner_T30 Activate for Drawshell
• Only the springback result of D-20 is available
(Free Springback at End of Operation).
• Clone for SB-Comp…

• Activate the option Create Restart.

109
 Modify Assign Drawshell Region
• Delete the Transition Region.
• Smoothing Factor = 1.00
• Activate Cut Curves (T-30).
• Select the tool: HoodInner_T30.
• Start the compensation with Apply.

110
 Trim Angle Analysis
• Analyze the trim angles after springback:

• Unskip the skipped operations and start the

simulation.

111
 Analysis: Binder Closing
• Contact Distance (Bottom Layer) • UDV: Unwanted Deformation

112
 Distance to Reference Geometry after the Compensation
• First Iteration (compensation of the draw stage and T-30 with Drawshell Mode)

113
 Second Iteration of the Compensation
• Second Iteration • For this reason the geometry Hoodinner D-20 is
blocked in the Compensator.

• Repeat the procedure for the second iteration:

• Clone for SB Comp…

• Use Recalculate All.

• The cloned file is still setup on a Restart.

114
 Second Iteration of the Compensation
• A change of the compensation strategy is not
required.

• Start the compensation with Apply.

• Only the Draw operation is simulated.

Skip the operations T-30, T-40 and M-50.

• Update the drawbeads:

Process D-20 Beads

• Start the simulation.

115
 Drawshell Compensation of T-30
• Clone for SB-Comp: • Result of springback compensation after the
• Activate the Restart option. 2. Iteration:

• Start the springback compensation with Apply.

• Remove Skip OP.
• Start the simulation.

116
 Compensation & Restart
• The Restart option for compensation requires an • It is not possible to switch off the Restart option in
.rst file of the base simulation. the Clone for SB-Comp menu:
• Switch on the appropriate Restart option on
Control page of the base simulation:

• Now Restart Options are available:

• Instead click the Clone button and use Recalculate

All in the new file:

117
www.autoform.com

Die Face-Use Case

Evaluation of the Springback Compensation at an Early Stage
 Why Compensate at the Early Stage?
• Check of the tipping

• Check of the trim angle limits

• Detect problems in time

• Flattening the part
• Adapt the method
• Make a request for metal gainers in the part

119
Exercise 8:

Die Face-Use Case

 Exercise 8: Die Face-Use Case
• Check the feasibility of the springback compensation of the Part Import simulation Brace_CE+.afd.
• Only the drawing operation is to be compensated.

T-60

F-50

T-40

T-30

D-20

121
 Clone for SB-Comp…

• Clone for SB-Comp…

• Position: At End of Modify Page

122
 Modify Assign Regions
• Define the compensation regions as
shown in the following picture.

• Start the compensation using Apply.

• Update the Die Face geometry: Go to the

Trimchk page and press Apply.

• Subsequently, start the first iteration.

• Check the trim angles and the Backdraft

analysis during compensation.

123
 Displacement in Normal Dir

Base simulation

1. Iteration

2. Iteration

124
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