iletisim: omarer25@hotmail.

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ALGHAFORM PAYLASIMIDIR
iletisim: omarer25@hotmail.com
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5 AutoFormTrim

AutoFormTrim is a module to determine either a blank outline or a

cut contour outline in connection with the AutoFormIncremental
solver so that the part reaches the defined target boundary at the
end of the forming process. Use AutoFormTrim for the following
typical cases:
Calculation of the customized blank sheet for crash forming parts
Calculation of the customized blank sheet for a predefined
target boundary of a drawing part
Calculation of the final cut contour in areas in which additional forming steps follow (e.g. second forming, bending
operation, flanging operation)
Precondition for the calculation of the blank outline and the cut
contour is a simulation with AutoFormIncremental containing all
necessary forming and cutting operations. Basing on this simulation
you define parameters for the calculation of the blank outline and
the cut contour.
The parameters for the calculation of a blank outline are the target
boundary of the part and the forming process after which the target
boundary has to be reached. Subsequently the outline of the initial
blank is modified iteratively by the simulation of all necessary
forming operations until the part has reached the target boundary
at the end of the forming process.
For the calculation of a cut contour with AutoFormTrim you need
the following input:
Cut contour to be optimized
Target boundary for the part
Forming process after which the target boundary has been
reached
Subsequently the contour of the defined cut is modified iteratively
by the simulation of all necessary forming operations until the part
has reached the target boundary at the end of the forming process.

With the current version 3.1 you can only calculate outer cut contours, no hole contours or inner cut contours.
The accuracy of the calculation of the blank outline and the cut contour depends on the chordal deviation of the FEA model for the
tools and the part.

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Contents of the Workshop AutoFormTrim

Lesson1

Blank outline optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Lesson 2

Optimization of a trimming cut outline . . . . . . . . . . . . . . . . . . 11

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Lesson 1: Blank outline optimization

5. 1 Lesson 1: Blank outline optimization

The following example shows how to use AutoFormTrim in order to optimize a blank
outline.
The following files are needed to run the example:
tr_lesson_01_basis.sim: The simulation with the blank
outline to optimize
tr_lesson_01_target.igs: The final outline

The simulation
Open the sim file tr_lesson_01_basis.sim
File > Open ... > Select a file > Files: tr_lesson_01_basis.sim > OK
Fig. 1.1

The initial geometry

Trim calculation
Open the Input generator and create Trim:
Input generator > Create > Trim

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Lesson 1: Blank outline optimization

Fig. 1.2

Create Trim
Then youve got a new page in the Input generator called Trim.
Fig. 1.3

The Trim page in the Input generator

On the Trim page, select the option Optimize blank outline:
Trim

Optimization type > Optimize blank outline

Target process step: Process step where you want to get the final
part with the correct outline.
Target process step: drawing which corresponds to the process step
where we want to get the correct outline at the end of the step.
Target Boundary: To give the correct target outline.
We must give the final outline we want to get at the end of the target process step.
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Lesson 1: Blank outline optimization

Target boundary > Import > IGES > tr_lesson_01_target.igs >
Curve 1 and Curve 2 > OK

Trim

(To select both Curve 1 and 2, first select curve 1 and then select
curve 2 while pressing the Ctrl key)
Max # of iterations: 5
We have to define the maximum number of iterations (maximum
number of simulations)
Max deviation: 1.2
We have to define the maximum deviation (mm) of the cutting contour from the target boundary.
Fig. 1.4

Selection of the target outline

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Lesson 1: Blank outline optimization

Fig. 1.5

The Trim page at the end of the input

Now you can launch the Trim calculation:
File > Save as > tr_lesson_01.trm
Job > Start trim > Save > Start
Fig. 1.6

Start trim
In this example, youve got the correct result in just 2 iterations.

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Lesson 1: Blank outline optimization

Trim results management

AutoForm saves in the trim file (tr_lesson_01_basis.trm) the informations concerning the different iterations it has made, and it creates files for each iteration of the Trim modulus
(tr_lesson_01_basis_trm1.sim, tr_lesson_01_basis_trm2.sim etc.).
Open the file tr_lesson_01_basis.trm to open the Trim manager:
User interface

File > Open trim ... > Select a file > Files: tr_lesson_01.trm

Fig. 1.7

The Trim manager

manager; open simulation 2
You get access to the following functions:
Convergence allows you to check the convergence for
each simulation and then choose the best one.
Open allows you to choose which simulation you want to
open, the basis simulation or one of the trim simulation.
Then you can choose the simulation you want to open (generally
the last one) and then export the optimized cut contour.
In order to do so, open the curve manager, select the contour you
want to export and export it.
Model > Curve manager >Blank outline > File > Export...

User interface
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Lesson 1: Blank outline optimization

Fig. 1.8

Export with the curve manager

Fig. 1.9

Blank outline, target boundary and part at the beginning of the calculation of the blank outline with AutoFormTrim

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Lesson 1: Blank outline optimization

Fig. 1.10

Blank outline, target boundary and part after the calculation of the
blank outline with AutoFormTrim

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10

Lesson 2: Optimization of a trimming cut outline

5. 2 Lesson 2: Optimization of a trimming cut outline

The following example shows how to use AutoFormTrim in order to optimize a trimming cut contour.
The following files are needed to run the example:
tr_lesson_02_basis.sim: The simulation with the cut outline to optimize
tr_lesson_02_target.af: The final outline

The Simulation
Open the sim file tr_lesson_02_basis.sim:
File > Open ... > Select a file > Files: tr_lesson_02_basis.sim
Fig. 2.1

The initial geometry

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Lesson 2: Optimization of a trimming cut outline

Trim calculation
Once the simulation is over, open the Input generator and create
Trim:
Input generator > Create > Trim
Fig. 2.2

Create Trim
Then youve got a new page in the Input generator called Trim.
Fig. 2.3

The Trim page in the Input generator

On the Trim page, select the option Optimize cut contour:
Trim

Optimization type > Optimize cut contour

Cut process step: to define the cutting process step where you want
to optimize the cut contour.

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12

Lesson 2: Optimization of a trimming cut outline

Cut process step > 2_cutting1 which corresponds to the trimming
cut operation
Target process step: Process step where you want to get the final
part with the correct outline.
Target process step > 4_abkanten which corresponds to the process
step where we want to get the correct outline at the end of the step.
Target Boundary: To give the correct target outline.
We must give the final outline we want to get at the end of the target process step.
Trim

Target boundary > Import > af > Keep orientation >

tr_lesson_02_target.af > Curve 4 > OK
Max # of iterations: 5
We have to define the maximum number of iterations (maximum
number of simulations).
Max deviation: 1.2
We have to define the maximum deviation (mm) of the cutting contour from the target boundary.

Fig. 2.4

Selection of the target outline

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13

Lesson 2: Optimization of a trimming cut outline

Fig. 2.5

The Trim page at the end of the input

Now you can launch the Trim calculation:
File > Save as > tr_lesson_02.trm
Job > Start trim > Save > Start
Fig. 2.6

Start trim
In this example, youve got the correct result in just 2 iterations

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14

Lesson 2: Optimization of a trimming cut outline

Trim results management

AutoForm saves in the first sim file (tr_lesson_02_basis.sim) the
informations concerning the different iterations it has made, and it
creates files for each iteration of the Trim modulus
(tr_lesson_02_basis_trm1.sim, tr_lesson_02_basis_trm2.sim etc.).
Open the tr_lesson_02_basis.trm file to open the Trim manager:
User interface

File > Open trim ... > Select a file > Files: tr_lesson_02.trm

Fig. 2.7

The Trim manager

manager; open simulation 2
You get access to the following functions:
Convergence allows you to check the convergence for
each simulation and then choose the best one.
Open allows you to choose which simulation you want to
open, the basis simulation or one of the trim simulation.
Then you can choose the simulation you want to open (generally
the last one) and then export the optimized cut contour.
In order to do so, open the curve manager, select the contour you
want to export and export it.
User interface

Model > Curve manager > Cut contour 1 > File > Export...
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Lesson 2: Optimization of a trimming cut outline

Fig. 2.8

Export with the Curve manager

Miscellaneous informations concerning the correct

use of the Trim modulus.
Always remember to select the Write Restart option in the Control
page of the Input generator for the basis simulation. The Trim modulus uses this restart file and you wont be able to create a trim
without it.
Fig. 2.9

Blank outline, target boundary and part at the beginning of the calculation of the cut contour with AutoFormTrim
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Lesson 2: Optimization of a trimming cut outline

Fig. 2.10

Blank outline, target boundary and part after of the calculation of

the cut contour with AutoFormTrim
In order to be sure of the Trim computation, follow these advice:
It is better to give a realistic initial trimming cut contour or
blank outline.
Try to make two calculations with two different initial cut
contours and then compare the results you get with the
two computations. If you get the same results, then youve
got the correct result.
Generally, AutoFormTrim gives the right result in less
than 5 iterations.

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17

Lesson 2: Optimization of a trimming cut outline

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