DIE FACE STAGE

Die Face Stage

The Die Face Stage consists of two sub chapters:

 Concept Geometry, available under AutoForm-DieDesigner license, includes functionalities

dedicated to the generation of the Concept Geometry of the dies according to the Production
Line and the Process Plan defined in the Plan stage.
 Quality Geometry, available under AutoForm-DieDesignerPlus license, incudes functionalities
dedicated to the generation of the Quality Geometry of the dies according to the Production
Line and the Process Plan defined in the Plan stage.

Die creation when the part shape is below the

binder
Solution or Workaround
When creating an addendum, the shape created depends on whether the part shape is located
above or below the binder.
You can change the position setting here:
Die Face Stage> D-20> Addendum > Settings > Part Position: Above Binder / Below Binder.
Die Designer cannot create a downward
convex die when planning a crash form
Solution or Workaround
Crashform is a function that assumes an upward convex shape.
Use a single action draw to create a downward convex tool

How to check which faces of the model

cannot be exported into a CAD system?
Solution or Workaround
Please use the command
Application Toolbar> Geometry > Analysis

This function shows in red color which faces of the model cannot be exported into the CAD
system.
(The surface colors differ depending on the AutoForm version)
How to connect separated faces generating
gaps inside the imported geometry?
Solution or Workaround
Using the combination of "Detail" and "Single hole" in Modify page can fulfill this requirement.
<Sample-1>
STEP-1 Go to the area where has gaps;
STEP-2 Use "Detail" feature to create a bridge between two patches;
STEP-2 Use "Hole>Single" feature to fill the remaining hole.

<Sample-2>
STEP-1 Go to the area where has gaps;
STEP-2 Use "Detail" feature to create connection by defining an area where covers two patches
(overlapping);
STEP-3 Add "Profiles" to better manage the filled area by generating inner edges.

This solution works in case the "Double Fill" is not available because the imported geometries
are not defined as double-attached. Use this solution only in case you have missing faces on a
single part when the symmetry plane doesn't exist.
Remark: The Detail feature is available if you have an add-on license for AutoForm-
StampingAdviser, AutoForm-DieDesigner, AutoForm-Compensator or AutoForm-HemPlanner.
How to control the height of an existing
depression/embossment generated by
Modify>Detail
Description

Is it possible to control the height of an existing depression/embosssment generated by

Modify>Detail?

Solution or Workaround
The height of an existing depression/embossment generated by the Modify>Detail module
can be controlled using the Shift option. Please note that in case of the round type, the control
curve doesn't represent the height of the top point.
There are several options offered to users to define the orientation of the direction used to
modify the position of the original control curve: Normal direction, Z-direction, View
direction or User Defined direction.

Remark: If you would like to create a material gainer which is a round type shape, please use
"Gainer" feature in Modify page. The height can be controlled directly in the dialog. Please
refer to below image.

AutoForm Version

Forming R8; Forming R10

Requirements
OS

How to create a double fill for multiple parts

e.g. 4 parts?
Solution or Workaround
The double fill features can be applied for multiple parts through several separated steps. Below
is an example showing how to manage the creation.
Step-1 To create the first double fill for two parts.
Step-2 To create the second double fill for the remaining two parts.
Step-3 To create the third double fill between surfaces generated in Step-1 and Step-2.
** Please utilize the same concept for the other multiple parts cases.
** Please note that double fill only works in symmetric or quasi-symmetric conditions.

Remark: The double fill feature is available if you have an add-on license for StampingAdviser,
DieDesigner, Compensator, and HemPlanner.

How to create a smooth transition between

multiple fillets?
Solution or Workaround
A smooth transition between multiple fillets can be performed through using the "Detail" feature
on the Modify page.

Below is an example showing how to manage the creation:

Step-1 Go to the junction area and then click on "Detail" button on the Modify page.
Step-2 Click on the "Input" button and then use the curve editor to define the shape and area.
Step-3 Click "Apply" to realize the result.
 As an alternative solution, you can also use the "Add Trim" feature to trim the boundary and
remove faces, and afterward use the "Fill Hole" feature to fill the holes. This solution will help to
improve the update-ability in case of a part change.
Remark: The Detail feature is available if you have an add-on license for AutoForm-
StampingAdviser, AutoForm-DieDesigner, AutoForm-Compensator or AutoForm-HemPlanner.

How to create a trim expansion curve in tool

data created by CAD
Solution or Workaround
Required data

 Part data
 Tool data

* Prepare data with the same coordinates and rotation angle for parts and tool data.

Procedure

1. Part Stage> Import> Import Part

2. Part Stage> Import> Import Tool Surface

3. Part Stage> Tip> Set tipping

4. Part Stage> Material> Set material
5. Plan Stage> Production> Create Empty Plan> Plan the draw process
 6. Plan Stage> Plan> D-20> Set the component trim unit on the outer trim

7. Die Face Stage> D-20> Modify> Select Insert

8. Select all shapes on the 3D view and add them to the Insert Cut Out
9. Click on Copy From...,select the imported tool data, click on OK and Apply

10. Enable and Apply the Trimcheck

The expanded curve can be exported from the application menu.

If you want to get the exact trim expansion curve, it is recommended to do the calculation once
and see the result

How to refine the embossment wall geometry

generated by Detail in a parametric way?
Solution or Workaround
The "Preform" can be used for this purpose:
STEP-1 Generate an emboss geometry by using the Detail feature.
STEP-2: Click on "Preform" feature to define the "Base Curve" firstly.
STEP-3: A preform surface is generated. The shape can be managed in a parametric way.
 How to use form check on die face stage
Solution or Workaround
Formcheck of the Die Face Stage:

 Estimated blank outline, estimated coil / part / blank weights/perimeters, estimated tool forces
and feasibility are calculated
 Simple fomarbility confirmation can be performed using the drawing die created in the drawing
process.
 Holding conditions can be defined and formability analyses confirmation can be performed
according to the inflow state of material.

* The Formcheck of the die face stage can be used only for the drawing (D) process.
To create a Formcheck on the DieFace Stage go to DieFace stage> Formcheck> Add
Formcheck

 Estimated result
By performing a Formcheck, the following results are estimated: Part Weight, Blank Weight, Coil
Weight, Utilization, Dev. Part Perimeter, Blank Perimeter, Coil Width, Coil Pitch

 Draw-In Blank

Define the blank outline line position after drawing

 By setting the constraint conditions, you can set an appropriately expanded blank outline

Example: Define the bottom dead center outline with the Draw-In blank and define the
appropriate restraining force with holding conditions

As a result, the minimum blank outline can be obtained, so the yield and formability can be
examined.

 Outer Holding Condition

By changing the slide bar from crash (0.000) to stretch (1.000), you can check the formability
according to the constraining conditions.

Crash: There is no constraining condition like a Crashforming

Stretch: No material flow like lock beads

 Part Cut Out / Variable Holding Condition

By adding a cutout of parts, you can specify the constraint condition of the added part

Example: When making a hole in the blank material and allowing it to flow from the inside

 By setting variable holding conditions, you can partially change the holding conditions on the
border
(Similar to the bead setting, there is a gradual change between the set variables.)

Blank Stage> Outline

 By performing a form check, the expanded blank shape can be used as a blank outline.

How to use Trim check

Solution or Workaround
Check tolerance limits for trims, piercings and developed cutting curves defined in the planning
stage
* Trim and piercing tolerance limits are defined in Plan Stage > Settings
* Trim check can be used in single action draw, double action draw, and crash form process.
Die face stage > Trim check page > Add Trimcheck
Settings - Offers the possibility to define the method to be used for the calculation of the
developed flanges.
・ Geometric (Approximate): The algorithm uses a geometric method to quickly approximate the
position of the developed curves onto the draw surface of the part geometry.
・ Physical (Accurate): The OneStep based algorithm uses a physical method to accurately
calculate the position of the developed curves onto the draw surface of the part geometry
・Consider Thickness: When the option is selected, the material thickness will be taken in
account for the calculation of the developed flanges.
(If you do not select this option, the midplane will be taken into account)

Trim Overlap

・ Clearance: The options Length and Depth define the clearance with respect to the trimming
curve.
・ Expansion: The option Length defines the extension with respect to the scrap splitting curve.
Trim analysis
・ Display Original shape: Shows the original part geometry flanges used to calculate the
developed curves
・ Display Developed Face Boundaries: Shows the face boundaries of the part geometry flanges
used to calculate the developed curves.
・ Draw-In: The Drawn-In line is used to calculate the value of the scrap diameter. It is located
on the binder ring and it is represented as a light blue dotted curve. The Draw-In line can be
displayed or hidden using its visibility switch control in the 3D view. When the Automatic function
is selected, the estimated Draw-In line is automatically generated about 40 mm from the P.O.
Line and/or the developed flange.

Add curve: Create a trim curve at any position

・ Copy: Create a trim curve by copying an existing curve
・ Edit: Add a curve, edit the copied trim curve
・ Edit trim plan: Edit the position of the trim curve created in the trim plan

Checking trim
Select the item you want to check from Application Toolbar> Geometry> Analyses.
Is it possible to reduce the fillet size by using
the Radius feature on the Modify page?
Solution or Workaround
The radius feature was only available for creating a fillet which is larger than original's so far, but
since R8 version, it is also possible to generate a fillet that size is smaller than the original one.
As usual, open the Radius feature, generate a centerline, define a smaller radius, then click on
Apply.

What is the major difference between

Fillet>Add Global fillet and Modify>Radius?
Solution or Workaround
Both features are filleting features.

Fillet>Add Global Fillet function is a very quick tool for Part Designers to detect Sharp Edges and
deform Fillets on each individual imported geometry in order to run a quick simulation e.g.
Formcheck to see whether if the fillet is OK nor not. This helps Part Designers to define
appropriate fillet within a short time. When the value of fillet is properly defined, then Part
Designers can use Modify>Radius feature to generate the Fillet Radius of the geometry
Furthermore, In case of Fillet>Add Global Fillet, fillets are created by deforming the existing
faces, which means that the user don't get separated patches of the fillets; Also the deformed
surfaces can't be exported.
In case of Modify>Radius, new fillet faces are generated after applying and the original walls are
trimmed. The user is possible to create/edit contact or various radius in a CAD-like way.