AutoForm Incremental PDF

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2 AutoForm–Incremental
AutoForm–Incremental is the AutoForm module to simulate sheet

metal forming processes (conventional deep drawing, hydrome-
chanical deep drawing) using the finite element method in many
small steps. Using AutoForm–Incremental it is possible to simulate
all forming operations beginning with the plane blank sheet and
ending with the finished car body part including springback calcu-
lation.
In AutoForm–Incremental the simulation of the following forming

processes or phenomena is possible:
• Impact of gravity when putting the blank sheet on the tool

• Binder closure (binderwrap)
• Drawing with/without drawbeads or lock beads
• Cutting
• Second forming
• Forming operations with cam slides
• Forming operations with die and punch inserts
• Springback
• Preforming the blank sheet by means of a fluid
• Hydromechanical deep drawing
Forming operations for steel and aluminum materials used in the

automotive industry as well as tailored blanks can be simulated
with AutoForm–Incremental. In connection with the easy–to–use
user interface the tool maker, the tool designer and the process engi-
neer can quickly verify the forming process in all tools and – where
required – optimize processes, to lay the foundations for high qual-
ity parts at the computer.
When entering the simulation input data, the user is guided by the
program and pointed at still necessary inputs. The movement of all
tools can be checked prior to the real simulation. In general the cal-
culation time for a simulation ranges from only a some minutes up
to a few hours.
Color shaded post values such as sheet thickness, cracks, strain and
stress as well as process parameters such as forces are available for
the evaluation of the simulation. Wrinkles are identified by inspect-
1
ing the shaded representation of the model or by means of color
shaded post values. These possibilities are completed by additional
special evaluation criteria such as skid/impact lines.
In connection with AutoForm–Optimizer, the user gets access to a

numerical optimization algorithm by which process parameters
such as binder force or restraining forces for drawbeads are auto-
matically modified during several simulation iterations to obtain an
optimally stretched part without cracks and wrinkles.
2
Contents of the Workshop „AutoForm–Incremental“
Lesson 1 Deep–Drawing on Double Action Press . . . . . . . . . . . . . . . . . 5
• CAD–Import–IGES
• Binder definition
• Input generator
• Blank definition
• Gravity
• Starting the simulation
• Evaluation of the simulation
Lesson 2 Deep–Drawing on Single Action Press.

Press. . . . . . . . . . . . . . . . . . . 27
• CAD–Import–IGES
• Positioning of tools
• Positioning the blank sheet
• Process definition
• Evaluation of the simulation
Lesson 3 Drawbeads and Tailored Blanks . . . . . . . . . . . . . . . . . . . . . . . 47
• Input generator
• Material definition
• Weld line
• Drawbead
Lesson 4 Drawbead generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
• Automatic determination of the width

• Automatic determination of the restraining force (Force-
factor) of a drawbead
Lesson 5 Tipping and Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
• Determination of the drawing direction

• Relief cut
• Trimming cut
• Holes
• Cutting direction
3
Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Lesson 6
• Numerical optimization
• Parameter study
• Optimization of the force factor of a drawbead
• Evaluating the optimization
Automatic Filleting with a Constant Radius . . . . . . . . . . . . . . 110 Lesson 7
• Automatic Filleting
• Defining the blank sheet by arc
• Restart
Multiple Step process and Starting from Restart file . . . . . . . . 120 Lesson 8
• Starting from Restart–File

• Definition of additional tools
• Definition of additional process steps
• Filleting radii
Using CAM Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Lesson 9
• Undercuts
• Adding tools
• Changing working direction
• Adding a process step
• Process type Flanging
Use of Pad and Springback.

Springback. . . . . . . . . . . . . . . . . . . . . . . . . . 154 Lesson 10
• Die insert (pad)

• Free contours, sharp edges and undercuts
• Definition of an additional tool
• Definition of additional process steps
• Altering tools
• Positioning of tools
Hydromechanical Deep Drawing . . . . . . . . . . . . . . . . . . . . . 173 Lesson 11
• Symmetry
• Forming by means of fluids
• Preforming
• Active hydromechanical deep drawing
4
Lesson 1: Deep–Drawing on Double Action Press
2. 1 Lesson 1: Deep–Drawing on Double Action Press
This lesson describes the deep–drawing process on a double action press. The CAD
data of the die is available.
Fig. 1.1
Deep drawing on a double action press
Generation of a Simulation file

At the beginning, a new simulation file (*.sim) has to be defined.
The first input is the name of the simulation. During the generation
of the input, this simulation file is filled with data, which is neces-
sary for the simulation (geometrical data, specification of process,
numerical data etc.).
The generation of the simulation file is done by the following input:
File > New ... > in_lesson_01 > OK
5
Fig. 1.2
Options to create a new simulation file
• File name: name of *.sim file, without extension

• Units: Units, which are used in this simulation file. This
should correspond to units used in CAD data.
• Geometric error tolerance: Acceptable chordal error of
mesh generation.
Preparation of tool geometries for the simulation

Normally the first input is the geometries of the tools used in this
simulation. AutoForm requires these geometries in VDAFS or IGES
format only. It is recommended that the user start with the input of
the geometries, because possible errors or missing data in the CAD
model can be checked and corrected early.
The tool geometries are read in VDAFS– or IGES format. AutoForm

automatically meshes the tool surfaces. All subsequent operations
are based on this mesh. Only the mesh can be visualized in Auto-
Form, not the original CAD data.
6
Import and meshing of CAD data

File > Import > IGES > OK
Fig. 1.3
Select a file: in_lesson_01.igs > OK
Fig. 1.4
Window to mesh CAD data
Start meshing with the option:
Program: afmesh_3.1 > OK
7
• Error tolerance: Acceptable chordal error for the meshing. Parameters

Value is taken from New file dialog (Default: 0,1) (Fig 1.1),
but it can be changed. For especially small radii (equal or
lesser than 2 mm) 0.05 should be used as error tolerance.
• Max side length: Maximum element side length
• Treat only: Only specified faces will be meshed. Faces

• Exclude: The specified faces are not taken into account for
meshing.
• Treat only: Only specified layers will be meshed. Layers

• Exclude: The specified layers are not taken into account for
meshing.
8
The meshed geometry is immediately displayed and the Geometry

generator automatically pops up. At first, the tool setup in the
Geometry generator has to be changed, so that the die is the lower
tool (right Icon in Fig. 1.5).
Fig. 1.5
In this example the CAD data is binder (binder) and punch

(punch). Later the die (die) is created with Offset. The two tools
have to be separated first. This is done as follows:
Select faces of binder (right mouse button or Shift – right mouse

button for several faces).
9
Fig. 1.6
Selected faces of binder
Define objects: Binder Prepare
Binder is defined in Geometry generator and selected faces are put

into the Binder register. The remaining unselected faces become the
punch and all faces are defined as the die; hence all required tools
for a standard simulation are now fully defined.
The next step is checking the geometry to see if it can be used for
simulation. AutoForm can check for free edges, sharp edges or
undercuts.
Control parameters can be found in Part boundary (Fig. 1.5):
• Error tolerance is the acceptable chordal error of the CAD

data describing the part boundary and the generated part
boundary of AutoForm.
• Concatenation distance is the minimum distance between
points on the part boundary.
10
Use button
Generate part boundary: Apply (Fig. 1.5 bottom right)
to start automatic calculation of the part boundary (shown in blue).
Fig. 1.7
Generated part boundary
If gaps occur in the geometry, several blue lines are displayed. This
is one possible way of checking for gaps and untrimmed surfaces. If
the generated part boundary needs to be changed, it can be done
using the option
Prepare Outer Trim > Edit
Holes can be created with the option
Inner Trim > Add…
Correction of untrimmed surfaces should be performed in CAD

system. Checking for sharp edges and undercuts can also be done in
Geometry generator. This is described in detail in Lessons 5 and 7.
11
Check geometry for sharp edges:
Geometry generator > Fillet > Check radius: 2.00 > Check Fillet
In the log–window, it is displayed that (no) sharp edges have been

found.
Close the window using Dismiss (Fig. 1.8).
Fig. 1.8
Fillet page of Geometry generator
12
Check geometry for undercuts using option:
Geometry generator > Tip (Fig. 1.9)
Fig. 1.9
Tip page of Geometry generator
All undercuts, marginal areas and undercut free areas are calcu-
lated and displayed in different color for the current drawing direc-
tion when the Tip page is opened. Undercut free areas are
displayed in green, marginal areas are displayed in yellow and
undercuts are displayed in red. This colored display can be chosen
with the option
Tip Display > Backdrafts in the Geometry generator.
13
Use the button Plot to activate the backdraft diagram (Fig. 1.9).
Generate simulation input

All further inputs are defined in the Input generator. Open the
Input generator:
Model > Input generator ... > Simulation type: Incremental
Fig. 1.10
Dialog: Simulation Type to create simulation input
• Simulation type: Incremental simulation, OneStep simula-

tion or Hydroforming of tubes
• Tool setup: Defines the tool setup with respect to z–axis (z–
axis points upward)
• Sheet thickness: sheet thickness
• Geometry refers to: Decide which side of the tool set the
geometry refers to (punch side or die side).
• No offset: None of the tools automatically gets an offset. In
this case, tool offsets should be created in CAD system and
different CAD geometries for punch and die should be
read in.
The current file contains binder and punch geometry. Therefore, the
die gets an offset (Geometry refers to: punch side).
OK opens Input generator.
14
Page Title (title of simulation) has a default text–string input which

can be changed. Comments is for the input of user–comments
regarding the current simulation. All inputs for the simulation need
to be completed before it can be executed: Inputs are missing on
pages that are marked conveniently with red letters.
Fig. 1.11
Input generator
The input on pages shown in black letters are already completed.

Nevertheless, all input data should be checked for meaningful val-
ues for current simulation. In the following example, only pages
marked with red letters are considered.
Tools Tools are defined on Tools page. Three tools (die, punch and
binder) have already been defined. The geometries of these tools
have been defined in the preparation phase of tool geometries for
the simulation.
15
Binder is marked in red on this page, because columns for the

binder must be defined. Columns are the input points of the force
for force–controlled tools. By default, the binder is predefined as
being a force–controlled tool. Therefore AutoForm requires this
input (see also Lessons 8 – 10). Columns have to be defined for
every force–controlled tool.
Columns for binder: It is recommended to use
Tool center
Option Rectangle ... on Blank page defines a rectangular blank out- Blank
line.
Tip:
Tip We recommend a view from positive z–axis (press Ctrl–Z
Ctrl Z).
Fig. 1.12
Blank page of Input generator
Outline > Rectangle ...
16
Menu Blank outline - Rectangle opens:
Fig. 1.13
Blank outline - Rectangle
Inputs can be done by using either the right mouse button or key-
board.
Use the right mouse button and sketch a rectangle to define a rect-
angular blank outline. The blank outline (blue) is displayed in the
main display (Fig. 1.14). In the menu Blank outline - Rectangle
(Fig. 1.13) modify the values as follows:
Blank Center x, y: 0, 0 Length X: 430 Length Y: 340

Fig. 1.14
Rectangular blank outline
Complete the definition of the blank outline by selecting
OK
17
A double action deep–drawing process is already predefined on the Process

Process page. Double action deep–drawing process means that the
binder moves until it closes with the die and then the punch moves
until it is fully bottom down. The duration of the different process
steps (Duration on Process page) depends on the positioning of the
tools with respect each other (Move on Tools page). By default, the
distances between the tools are 500 mm.
Fig. 1.15
Process page of Input generator
For this example only inputs for process step named gravity are
missing (Fig. 1.15):
gravity > Gravity: downwards

die: Stationary
18
Control – Input of numerical parameters

Fig. 1.16
Control page of Input generator
For sheet thickness greater than 1.5 mm: select ThickSheet/Spring-

back in later restart
Tip:
Tip If button ThickSheet/Springback in later restart is activated, the
simulation is done using 5 layers.
In addition to the preselected result variables, the following are

selected:
Rslts > Contact distance above

Rslts > Contact distance below
Rslts > Curvature
Start of simulation
Job > Start simulation ... > Start job > Program: af_3.1 > Start
19
Fig. 1.17
Start Job window
Only one simulation can be started with one license. Other simula-
tions that are ready to start can be put into a queue (Queue). The
simulation job can be put at the top or bottom of the queue.
Kinematic check only checks the tool movement only. This is com-
pleted in a few seconds. This functionality helps avoid possible
errors of the tool movement or tool positioning and is recognized
during the simulation. If this button is activated, only the tool
movements are calculated and displayed. The blank remains unde-
formed.
The results are saved in the simulation file after start of the calcula-
tion (Kinematic check only not activated).
File > Reopen

opens the *.sim file again, and results can be analyzed.
At each time–step of the analysis, the Input generator can be opened

to review or change the input or define another simulation because
the input data is also saved in the *.sim file as the results.
20
Analysis of results (colored display of result vari-

ables)
In the following the analysis of the most important result variables
will be discussed. These results can be displayed both as colored
and shaded images.
Re–open the simulation file (*.sim) after the calculation is completed

successfully.
File > Reopen

To go to the end of the simulation use
Time > End of simulation or hotkey Ctrl – E.
Moving the mouse over the icon panel on the right side of the main
display shows the names of each of the icons.
Activate the display of Formability results with button Formability

(shown in second row of result buttons in main display).
Fig. 1.18
Result variable Formability
21
• Cracks: Areas of cracks. These areas are above the FLC of

the specified material.
• Excess. Thinning: In this area, thinning is greater than the
acceptable value (default value for steel is 30%).
• Risk of cracks: These areas may crack or split. By default,
this area is in between the FLC and 20% below the FLC.
• Safe: All areas that have no formability problems.
• Insuff. Stretching: Areas that have not enough strain
(default 2%)
• Wrinkling tendency: Areas where wrinkles might appear.
In these areas, the material has compressive stresses but no
compressive strains
• Wrinkles: Areas where wrinkles can be expected, depend-
ing on geometry curvature, thickness and tool contact.
Material in these areas has compressive strains which
means the material becomes thicker during the forming
process.
In this example, wrinkles can be expected in the center of the part

geometry and in the binder area. The part does not show any cracks
or excessive thinning.
The default–values of result variable Formability can be changed in

the following menu:
Results > Formability …

Fig. 1.19
Dialog: Formability
The small plot shows the different areas with respect to the FLC.
22
Switch to result variable Thinning (second row of icon panel in

main display, middle button). A scale is displayed in the lower part
of the main display with a range of 30% thinning to 3% thickening
colored from yellow to green (depending on the specified color set-
tings). The exact thinning value (in percentage) is displayed, when
you click with the right mouse button on the geometry. Hit the Esc
key to clear these labels from the display. To find the maximum
thinning and the maximum thickening of the part use the following
options (Fig. 1.20)
Results > Show max

Results > Show min
Fig. 1.20
Display of result variable Thinning with min and max values
To change the displayed range of the scale use the following option
(Fig. 1.21)
Result > Ranges
23
Fig. 1.21
Dialog: AutoForm - Min/Max Editor
• Min/Max Simulation: Use min and max values of the

whole simulation.
• Min/Max Increment: Use min and max values of the cur-
rent increment.
• Simulation default: Use default min and max values.
• Manual: Use user–defined min and max values.
Change the values for the scale manually:
Manual: Min. 0.0 Max. 0.05
The display should correspond to Fig. 1.22. All areas without thick-
ening are displayed in yellow.
24
Fig. 1.22
Display of result value Thinning with min value 0.0 and max value
0.05
Switch to result variable Failure (maximum) (first row of icon panel

in main display, middle button). Deactivate the display of the min
value with following option (Fig. 1.23)
Results > Show min
25
Fig. 1.23
Display of result value Failure (maximum) with max value
No values > 0.8 are shown for this example. This means that no
cracks can be expected for the deep drawing of this part.
Close AutoForm–User Interface

The user interface can be closed with following option:
File > Quit or hotkey Ctrl – Q.
26
Lesson 2: Deep–Drawing on Single Action Press
2. 2 Lesson 2: Deep–Drawing on Single Action Press
In a single action press, the die is mounted to the ram of the press. Punch and binder
are mounted on the press table. The blank lies on the binder. Sometimes the punch
supports the blank, to avoid bending of the blank due to gravity. During the forming
process the ram moves down and at first the die closes with the binder and the blank is
fixed between these tools. The die then displaces with the binder during the ongoing
movement of the ram and the part is formed over the fixed punch. The position of the
tools is shown in Fig. 2.1.
Fig. 2.1
Tools in a single action press
The tool setup is the opposite of setup for deep drawing on double
action presses (see Lesson 1).
For an AutoForm simulation a double action deep drawing process

is predefined by default. This can be changed to a single action pro-
cess. One has to adjust
• Tool positioning (Tools page of Input generator)

• Initial position of blank (Blank page of Input generator)
and
• Process steps (Process page of Input generator)
27
Keep in mind that for a single action process, tool geometry is

always taken from CAD. In nearly all cases only one side of the tool
exists and the other side is generated in AutoForm with Offset
option. This means that the initial position of the tools is the same.
At first the tools are opened (Tools page) and during the forming
process they are closed (Process page).
For a double action process the distance at which the tools are
opened does not matter because in AutoForm the tools always
move in a single increment until initial sheet contact is made. Subse-
quently, the incremental displacements are used only during the
forming of the sheet. Using a double action process, the tools move
until contact with the sheet is made without any movement of the
sheet itself. The initial positioning of the tools has to be such that
there is no penetration between the tools and blank.
In a single action process the positioning of the tools is very impor-

tant. The distance of binder and punch has to reflect the real dis-
tance in the press. The distance between binder and die does not
influence the simulation. The reason is that the blank lies on the
binder and the die moves initially until it comes into contact with
the sheet. During drawing, the die displaces both binder and sheet
and due to this movement of the sheet, AutoForm uses the incre-
mental displacement. If the distance between binder and punch is
too large, it can lead to long calculation time and unrealistic results.
Therefore it is important that the tool positioning for a single action

process in AutoForm simulations should be the same as in the real
press.
Preparation of simulation
Open a new simulation file:
Geometry generator opens.
File > Import ... > IGES > OK > in_lesson_02.igs > OK > Program:
afmesh_3.1 > OK
Prepare > Select faces of binder (right mouse button) (Fig. 2.2).
28
Fig. 2.2
Geometry with selected binder patches
Prepare > Define objects: Binder
Now the selected patches are defined as binder, unselected patches

are defined as punch and all patches are defined as die.
Check geometry for gaps:
Geometry generator > Generate part boundary: Apply
Geometry generator > Fillet > Check radius: 2.00 > Check
A message that (no) sharp edges have been found appears in the
log–window. Close this log–window with Dismiss.
Check geometry for undercuts:
Geometry generator > Tip
lated and color displayed for the current drawing direction when
Tip page is opened (see Lesson 1 for a detailed description of Tip-
ping options). Undercut free areas are displayed in green, marginal
areas are displayed in yellow and undercuts are displayed in red.
This colored display can be switched on or off with the option
Display > Backdrafts in the Geometry generator.

29
Use button Plot to activate the backdraft diagram (see Lesson 1 for
more details).

Model > Input generator ... > Simulation type: Incremental > OK
Title is predefined but it can be changed.
Columns for binder has to be defined on Tools page. It is recom-

mended to use:
Tool center
Option Rectangle ... on Blank page defines a rectangular blank out- Blank
line. Inputs can be made by either using the right mouse button or
keyboard. Use the right mouse button and drag a rectangle to
define a rectangular blank outline. The blank outline (blue) is dis-
played in the main display (Fig. 2.3). In menu Blank outline – Rect-
angle modify the values as follows:
Center x, y: 0, 0 Length X: 430 Length Y: 340
Fig. 2.3
Rectangular blank outline
Finish the definition of the blank outline with
OK
30
Adjust input for a single action process

All changes are done in Input generator.
Modification of tool position (Tools page)

The tool position has to be changed for a single action process. The
punch is fixed on the press table. Therefore it is recommended to
use punch position as reference.
punch > Working direction > Move: 0 (Fig. 2.4).
Fig. 2.4
Position punch
Binder should be moved by 65 mm in working direction (Fig. 2.5). It

is positioned slightly above the punch to avoid excessive bending of
the sheet due to gravity. In AutoForm, the working direction is
always defined with respect to the blank. It is calculated automati-
cally, if the tool setup is correctly defined on the Prepare page of
Geometry generator.
31
Fig. 2.5
Position binder
Any position of the die can be chosen but it is important that the die
and the sheet do not intersect. In this example, the position of the
die is chosen as being 565 mm opposite to working direction.
die > Working direction > Move: -565 (Fig. 2.6).
This value is used to allow 500 mm for the closing of the die and
binder + 65 mm for forming.
32
Fig. 2.6
Position die
These adjustments lead to following initial tool position (Fig. 2.7):
33
Fig. 2.7
Initial position of tools
Modification of initial position of blank (Blank page)

The initial blank position can be modified on Blank page. For a
double action process, the blank is positioned on the die. This is the
AutoForm default. For a single action process, the blank has to be
positioned on the binder.
Input generator > Blank > Position > On: binder (Fig. 2.8)
34
Fig. 2.8
Blank page: Blank is positioned on binder.
Use material Zste180bhZ_1 from the database with thickness 1.0

mm:
Input generator > Blank > Properties > Thickness > 1.0
Warning: Tool offset adapted due to new average blank thickness.

Select OK.
Input generator > Blank > Properties > Import ... >
Steel_General+Europe > zste180bhZ_1.mat > OK
Lube Here the friction coefficient between sheet and tools can be speci-
fied. By default (Standard), a single value of the friction coefficient
is used for all sheet/tool contacts. It is recommended to use 0.15 for
sheet–steel and 0.18 for aluminum. Different friction coefficients can
be specified for tools above and below the sheet or for each of the
sheet/tool contacts (Fig. 2.9).
35
Fig. 2.9
Lube page: Definition of friction coefficient – Standard 0.15
Modification of process steps (Process page)

Two modifications have to be made on Process page:
• tool movements and

• duration of process steps.
gravity > Gravity: Downwards > Tool control > Show all > Gravity
die: Non-active > punch: Stationary > binder: Stationary (Fig. 2.10)
36
Fig. 2.10
Input page for gravity
Binder Wrap During binder wrap, the die is moving towards the binder and the
binder and the punch are stationary.
closing > Tool control > Show all >

die: Displcmnt > Velocity: 1 > Set
punch: Stationary > binder: Stationary
Duration of a process step depends on the distance of the contacting

tools (see Tools page). In this example, the distance between the die
and the binder (500 mm) determines the duration:
Duration > During time > Time: 500 (Fig. 2.11)
37
Fig. 2.11
Input for binder wrap (closing

closing)
closing
During the drawing process, the die is moving towards the punch, Drawing
the binder is force–controlled and it is displaced by the die. The
punch is stationary.
drawing > die > Displcmnt > Velocity: 1 > Set >
punch: Stationary
binder > Force > Relative tool: die > Const pressure > Value: 3 > Set
Duration of this process step depends on distance between punch

and binder (65 mm):
38
Fig. 2.12
Input for drawing process step
Job > Start

Tool movement can be checked with option Kinematic check.
If the punch should support the blank during gravity, the binder
position must be changed on the Tools page and duration of the
drawing process step (drawing) must be changed on the Process
page.
Start the Simulation

Job > Start simulation ...
Analysis of the simulation results (part2 – punch

contact, wrinkles, skid lines, sections, FLD, tool
forces)
When the calculation is finished, reopen the simulation file (*.sim)
with
39
File > Reopen

Punch contact
In order to ensure that deep drawn parts have a high level of quality
after deformation, it is important for them to have uniform initial
punch contact, especially for outer panels. This can be checked as
follows:
Display > Fill styles > Tools: Filled mesh > Sheet: Filled
Activate display of the punch: click the button punch in the user
interface (right side, below the buttons for sheet, blank and geome-
try). Set time to the end of binder wrap (closing).
Time > closing

Modify the display by clicking with the left mouse button in the
scale area right of the slider and then click the right mouse button
twice (Time 512).
The punch is visible through the sheet and initial punch contact can
be analyzed.
Fig. 2.13
40
Wrinkles
It is necessary to visualize the sheet in shaded mode and to display
all increments (animation) to analyze wrinkling during drawing
process. Some increments have to be analyzed in detail if wrinkles
occur. Deactivate the display of the punch (select the punch button
in the main display again). Start the animation of the drawing pro-
cess:
Time > Animate start or use hotkey Ctrl – A

If a single increment needs to be analyzed in detail, stop the anima-
tion using Ctrl – A.
You can also use menu option
Time > Times …

and then select one of the available increments in the Time menu. A
surface deviation can be seen in Fig. 2.14.
Fig. 2.14
Surface deviation of 10 mm before bottom down
41
Skidlines
Skidlines occur, if the sheet is drawn over small radii of the tool
with a certain contact pressure at a certain contact angle. Areas
where skidlines occur are normally in drawing radius regions.
Skidlines can be visualized with the following option:
Results > Tool marks

In menu AutoForm - Toolmarks
File > Read from File > in_lesson_02_toolmark.af > OK

Tools > Project onto > die > Accept
Define > Skid/Impact line
File > Dismiss
Use menu option
Time > Simulation end or hotkey Ctrl – E

to go to simulation end. Skidlines are now displayed as blue lines
and the movement and position of these lines can be analyzed (Fig.
2.15).
Fig. 2.15
Visualization of skid lines at simulation end
The display can be deactivated with following option:
Results > Skid/Impact line … > Select line with left mouse button
> Display > Clear all > File > Dismiss
Sections
Sometimes it is necessary to analyze the sheet/tool contact with
dynamic sections. Activate display of all tools
42
Display > Tools … > Show all
Use hotkey Ctrl – D to open Dynamic section menu.

Define a section plane (Fig. 2.16)
A x y: -200, 0 B x y: 200, 0
and select option Section in Dynamic section menu:
• Option Section displays the selected section plane as a 2D–

curve
• Option Clipping displays 3D geometry with the selected
section plane as a clipping plane.
Fig. 2.16
Dynamic section menu with defined section plane and activated

option Section
Press the button Apply in the Dynamic section menu. The 2D sec-
tion is displayed in the main display (Fig. 2.17).
Fig. 2.17
Dynamic section with option Section displayed in the main display
43
Deactivate Dynamic section with the option:
Dismiss
Deactivate the display of all tools:
Display > Tools … > Clear all

Forming Limit Diagram (FLD)
The Forming Limit Diagram (FLD) is a method to predict material
failures. The Forming Limit Curve (FLC) (measured strains above
which cracks occur) is displayed in black in the FLD. Major/minor
strains of all finite elements are shown in this diagram. Cracks and
process stability can now be analyzed. This diagram is activated
with the option:
Results > FLD then
Time > Simulation end or hotkey Ctrl – E to go to the simulation

end.
Strains of all elements are displayed in the FLC diagram by select-

ing the Show all button (top right – see Fig. 2.18). In this example all
elements are far away from the FLC, which means that no cracks or
splits are predicted and the process is quite stable.
44
Fig. 2.18
Forming Limit Diagram with all elements displayed at the simulation

end
Deactivate the diagram with
Dismiss
Forces
Tool forces are of great interest for the forming simulation analysis.
In this example, the display of the punch force over punch stroke is
described.
Keep in mind that the calculated force is only a rough estimation of

the actual force, because friction forces of the press and coining
effects are not taken into account. As a rule of thumb, the calculated
forces should be multiplied with a factor of 2 to 2.5 for the actual
force.
Activate AutoForm - Process data menu with option:
45
Results > Process data …
Deactivate forces for the die and binder:

Calculated reaction forces > die
Calculated reaction forces > binder
A calculated punch force of about 300000 N is necessary at bottom

down (Fig. 2.19) to form the part. This would mean in reality a
punch force of about 75 tons.
Fig. 2.19
Calculated punch force over process time
Deactivate the menu with
Dismiss

46
Lesson 3: Drawbeads and Tailored Blanks
2. 3 Lesson 3: Drawbeads and Tailored Blanks
This lesson mainly covers drawbeads and tailor–welded blanks. In AutoForm you can
define any number of drawbeads or weld lines.
Fig. 3.1
Drawbeads (red lines) and weld lines (blue lines)
Tailored Blanks
In AutoForm you can define any number of weld lines. This defini-
tion is done in the Input generator. Weld lines can have the follow-
ing shapes:
• Simple joint (weld line from one blank boundary to

another blank boundary) (Weld line 1 in Fig. 3.1)
• T–joint (weld line from weld line to blank boundary) (Weld
line 2 in Fig. 3.1) and
• Patch (closed weld line, patch is welded into a blank)
(Weld line 3 in Fig. 3.1)
A new simulation is created for this lesson, similar to Lesson 1.
Generation of a Simulation file

The generation of the simulation file is done with the following
input:
47
Preparation of tool geometries for the simulation

Reading and meshing CAD model:
File > Import ... > VDAFS > OK > in_lesson_03.vda > OK >
The meshed geometry is immediately displayed and the Geometry

generator automatically pops up. At first the tool setup in the
Geometry generator has to be changed, so that the die is the lower
tool (right icon in Fig. 3.2).
Fig. 3.2
Prepare page of the Geometry generator
48
Now the binder has to be defined in order to separate the geometry

into punch, die and binder.
Select faces of binder (right mouse button or Shift + right mouse

button for several faces).
Fig. 3.3
Selected faces of binder
All tools are now defined (see Lesson 1 for details). Now the blank
boundary has to be generated. Use the button
Generate part boundary: Apply (right bottom in Fig. 3.2)
to start automatic generation of part boundary. Part boundary is

displayed in blue (Fig. 3.4).
49
Fig. 3.4
Generated part boundary
Geometry generator > Fillet > Check radius: 2.00 > Check
In the log–window it is displayed that (no) sharp edges have been

found. Close this window using Dismiss.
Check geometry for undercuts using option:
Geometry generator > Tip
lated and displayed in different color for the current drawing direc-
tion when the Tip page is opened (see Lesson 1 for more details on
using the Tip function). Undercut free areas are displayed in green,
marginal areas are displayed in yellow and undercuts are displayed
in red. This colored display can be chosen with the option
Display > Backdrafts in the Geometry generator.
Use the button Plot to activate the backdraft diagram.

All further inputs are defined in the Input generator. Open the
Input generator:
Binder is marked in red on this page, because columns must be Tools

defined.
50
Columns for binder: It is recommended to use
Tool center
Blank Outline > Copy from... > Select curve (Fig. 3.5) > Bndry (Pre) 1 >
OK
This option on Blank page creates a blank outline which is identical

to the part boundary (Fig. 3.4).
Fig. 3.5
The menu Select curve shows all generated lines – here the part
boundary should be selected to generate a blank boundary that is
identical to the part boundary.
Edit the blank boundary now:
Outline > Edit ... > Curve editor (Fig. 3.6) > Global mod > Convex >
move slider to max. value (right side) > Expand: 40 > OK
Fig. 3.6
Settings on Global mod in Curve editor–menu

editor
Definition of a On the Blank page, several modifications have to be made to define

weld line a tailor–welded blank. Weld lines are always added in lower section
of the Blank page (Fig. 3.7).
51
Fig. 3.7
Blank page: Add weld ...
Weld menu opens, for which inputs have to be completed.
Fig. 3.8
Weld menu
52
Options for generating a tailor–weld blank:
• Weld line: Position and orientation of the weld–line is

defined here.
• Properties: These are the properties of one part of blank,
which can be changed in comparison to the basic or refer-
ence blank (At least one of these properties has to be
changed.).
• Thickness: Thickness of the blank
• Material: Material of the blank
• Angle: Rolling direction
• Properties apply at: A right mouse button click on one of
the blank regions, which are joined with the weld line,
defines the region for which the new properties (i.e., thick-
ness, material and angle) are valid.
Weld line > Input… > Curve editor > Define weld line with right
mouse button (the start– and end points lie on the blank boundary)
> OK
Weld line is accepted (Fig. 3.1 – Weld line 1).
A weld line joins two different parts of a blank. Properties of one

part of blank are already defined on Blank page. Properties for the
other part of the blank have to be defined on the Weld page. In this
example the thickness of the two halves is different (0.8 mm and 1
mm):
Properties > Thickness: 1 (Fig. 3.9)
Fig. 3.9
Definition of new thickness

53
Click > A right mouse button clicks on the blank region, for
which the new properties are valid (right part) > OK
After pressing OK button, a dialog (Fig. 3.10) asks if the automatic

tool offset should be calculated based on the average thickness.
Fig. 3.10
Dialog to adjust automatically offset to average thickness
OK – (on Tools page the offset is 0.9 =(0.8+1.0)/ 2) (Fig. 3.11).
Fig. 3.11
Tools page – new offset is automatically used
To define a second weld line, select the Add weld ... button on the Definition of a T–
Blank page again (Fig. 3.7). The Weld–menu appears again. Now Joint
the properties of the second weld line have to be completed.
Add weld ... on Blank page
Weld line > Input > Define weld line using right mouse button
(start point lies on the first weld line and the end point lies on the
blank boundary) (Fig. 3.1 – Weld line 2) > OK
Properties > Thickness: 2 (Fig. 3.12)
Click > A right mouse button click on the blank region, for which
the new properties are valid > OK
54
Fig. 3.12
New thickness will be defined
Again the dialog appears which asks if the automatic offset should
be calculated as the mathematical average of the three thickness val-
ues (see Fig. 3.10)
OK – on Tools page the offset is 1.2667 – ((0.8 + 1 + 2) / 3)
Definition of a Menu to add a weld line

closed weld line
(patch–work) Add weld ... on the Blank page
Weld line > Input > Define a closed weld line using the right
mouse button (Fig. 3.1 – Weld line 3)
Properties > Material > Import ... > zste180bhZ_1.mat > OK (Fig.
3.13)
Click > A right mouse button click on the blank region, for which
the new properties are valid (new material) > OK
55
Fig. 3.13
The new material will be defined
Using this procedure, any number of weld lines can be defined for a
simulation. After launching the simulation, AutoForm will create
the blank and the properties of the defined areas can be examined.
This examination is not possible prior the launch of the simulation
since (before the simulation) only the boundaries are defined and
the blank does not exist yet.
Drawbead
In AutoForm a drawbead is defined using only a bead center–line
and not with the real bead–profile geometry. This line specifies the
position of the drawbead. Furthermore a restraining force is speci-
fied which depends on the real profile geometry.
It is also possible to use the geometry of the drawbead, but that is

not recommended. Advantages of the drawbead model are:
• Simulation time is shorter, because the drawbead geome-

try with its small radii does not need to be geometrically
formed by the mesh (hence fewer elements are necessary).
• Changes or optimization of the drawbead position or
drawbead force can be achieved easily and quickly within
AutoForm directly. In contrast, changes to the real profile
geometry of the drawbead have to be made in a CAD sys-
tem which takes much more time and effort.
56
AutoForm now offers a Drawbead generator for the correlation of

the real profile geometry of drawbeads and drawbead force. With
the Drawbead generator the real geometry of the drawbead can be
specified and the force factor is automatically calculated by Auto-
Form. If the force factor is known, the Drawbead generator will
determine the real geometry of the drawbead. Use of the Drawbead
generator is described in Lesson 4.
Fig. 3.14
To define a draw bead an additional page has to be added to the
Input generator.
Add > Drawbead ... (Fig. 3.14) > Add drawbead > OK
A new page is added to Input generator (Fig. 3.15).
Fig. 3.15
Drawbead page (Drwbds

Drwbds)
Drwbds
57
Functions for generating a drawbead:
• Name: Name of a drawbead can be specified.

• Tools: Tools are defined; drawbead is active when these
tools are closed.
• Input ...: Position of drawbead line can be specified (Curve
editor).
• Import ...: Drawbead line is imported from CAD.
• Copy from ...: Drawbead line is copied from an existing
line. Base line and drawbead line are treated as different
lines.
• Dependent ...: Drawbead line is created from an existing
line. Drawbead line is a reference to the base line. This
means only the base line can be changed and the depen-
dent drawbead line will also change correspondingly.
• Position: Displacement of drawbead line in x–y plane
• Width: Width of a drawbead
• Forcefactor: Force factor of a drawbead
Drwbds > Name: bead1 > Above: binder > Below: die
Drawbead line > Input ... > Define drawbead line using the right
mouse button (Fig. 3.1 – bead 1) (For symmetrical parts drawbead
lines should intersect the symmetry line) > OK
Width: 15 Forcefactor: Medium: 0.35
An additional page has to be opened on the Drwbds page to add a

second drawbead. This can be done in the Input generator with the
menu option:
Add > Drawbead ... > Add drawbead > OK
or on Drwbds page using button
Add Drawbead ... (Fig. 3.15 left lower corner) > OK
A dialog asks if the new drawbead should be generated with

parameters of an existing drawbead. Fig. 3.16 shows that parame-
ters of bead1 are used. Only the drawbead line has to be specified
for bead 2. All other input parameters are automatically taken from
bead 1 (Fig. 3.17).
58
Fig. 3.16
Dialog asking for reference beads
Fig. 3.17
Only the line needs to be defined for the second bead
The position and length of the second drawbead line will be defined
using existing part boundary (Bndry (Pre)1).
Drawbead line > Copy from ... > Select curve > Bndry (Pre) 1 (Fig.
3.18) > OK
59
Fig. 3.18
Select curve
curve–menu
The second drawbead line is modified:
Drawbead line > Edit ... > Curve editor > Global mod > Expand: 20
> Trim (Fig. 3.20) (Length of a drawbead will be defined. Start point
is defined using the right mouse button (Fig. 3.21) and end point is
defined using Shift – right mouse button (Fig. 3.22)) > OK
Fig. 3.19
Drawbead line is expanded on the Global mod

mod–page in Curve
editor–menu.
Fig. 3.20
Trim page in Curve editor–menu

editor
60
Fig. 3.21
Start point of a drawbead line
Fig. 3.22
End point of a drawbead line
Process Only inputs for process step gravity are missing on Process page
(Fig. 3.23):
Process > gravity > Gravity: Downwards
Tool control > die: Stationary
61
Fig. 3.23
Definition of process step gravity
Control – Input of numerical Parameter

WriteRestart > off (Fig. 3.24)
WriteRestart ON means that a restart file (*.rst) is created. This file

contains all data that is necessary to restart the simulation from a
particular time.
Restarts can be used to save time, e.g. for multi stage processes, the
different forming processes can be simulated one after the other.
The disadvantage is the size of the *.rst file which requires greater
disk space.
Taking into account the speed of AutoForm, the restart option is

only useful for large parts (e.g. side panel, floor panel). In Lesson 8
(Multiple Step process and Starting from Restart File), this option
is described in complete detail.
62
Fig. 3.24
Control page of Input generator – WriteRestart disabled
Following results variables are switched off on Rslts page:

Rslts > Curvature
Start of simulation
File > Reopen …
63
Lesson 4: Drawbead generator
2. 4 Lesson 4: Drawbead generator
This lesson describes in detail how the width, the force factor and the restraining forces
of a drawbead are determined automatically. The values are determined in the Draw-
bead generator and have to be input manually in the Input generator.
Drawbead generator calculates the values Width and Forcefactor

for a defined drawbead. These are dependent on
• geometry of the drawbead,

• sheet thickness,
• friction,
• forming velocity and
• material
These two values have to be specified manually in the Input genera-

tor (Drawbead page > Width and Forcefactor).
Warning:
Warning The function is currently a Beta–Version. This is mainly due
to insufficient comparisons between the results of Drawbead gen-
erator and actual stampings at present.
First a simulation file has to be created to use the Drawbead genera-

tor, as was done in previous lessons.
Open example simulation file in_lesson_04.sim:
File > Open ... > Select a file > in_lesson_04.sim > OK
The drawbead generator is opened with
Model > Drawbead generator ...
64
Fig. 4.1
Drawbead generator
First the name of the drawbead is necessary (Name:). This name has
to be the same as the drawbead defined in the Input generator.
Then the type of drawbead has to be specified. The Drawbead gen-

erator offers three options: drawbead, lock bead and lock step.
The drawbead type is specified with the buttons shown in Fig. 4.2.
Menu for selecting drawbead, lock bead or lock step
Fig. 4.2
65
Different geometrical parameters are necessary for the different

drawbead types.
Drawbead geometry (Shape)

Drawbead
A drawbead is defined with the following parameters (Fig. 4.3):
• Radius R: Draw in radius

• Height h: Height of drawbead
• Radius r: Radius of drawbead
• Clearance c: Clearance
These parameters can be changed graphically by moving the

dashed lines (Fig. 4.3) or directly with the input fields for the
parameters.
The dashed lines can be moved with the left or right mouse button.
Use the middle mouse button to zoom in and out. Click once with
the middle mouse button to fit to window.
Fig. 4.3
Parameters to describe a drawbead
Lock bead
A lock bead is defined with the following parameters (Fig. 4.4):

• Height h: Height of lock bead
• Radius r: Radii of lock bead
• Width b: Width of lock bead
66
The parameters can be changed graphically by moving the dashed

lines (Fig. 4.4) or directly with the input fields for the parameters.
Fig. 4.4
Parameters to describe a lock bead
Lock Step
A lock step is defined with the following parameters (Fig. 4.5):

• Height h: Height of lock step
• Radius r: Radius of lock step
Fig. 4.5
Parameters to describe a lock step
The parameters can be changed graphically by moving the dashed

lines (Fig. 4.5) or directly with the input fields for the parameters.
67
Forces
The middle part of the Drawbead generator window shows results
of the calculation of restraining forces and hold down force (Fig.
4.6) and the diagram allows the user to determine the profile geom-
etry of the bead for a given restraining force.
Fig. 4.6
Forces
Under the Result option, the user can decide whether the Force fac-
tor (forces with respect to yield stress and thickness) or the Line
force (forces in N/mm for a 1 mm line) is to be calculated. These cal-
culated forces (Restraining force and Hold down force) are shown
below.
The drawbead graphics window shows calculated forces based on

the specified geometric parameters (R, h, r, c and B). The vertical
line can be moved (with right or left mouse button) and the calcu-
lated forces are updated immediately. Depending on the specified
geometric parameter, (e.g. r) the geometry of the drawbead profile
also changes. With this option the user can find the geometry profile
of the drawbead for a given force (e.g. a result of an optimization
run).
Parameters for process

In the lower part of the Drawbead generator, parameters for the
process can be specified which influence the calculated forces (Fig.
4.7).
68
Necessary inputs are for
• Sheet Thickness
• Friction
• Forming Velocity
• Material
• One drawbead or outer drawbead (single) or inner draw-
beads (double)
Fig. 4.7
Inputs for process parameters
If double drawbead are used, the button named double is used to

specify the inner drawbead of these two. The outer drawbead can
be specified by selecting outer DB:.
If one of the process inputs in the Drawbead generator window is

changed, the forces are recalculated.
More drawbeads can be created with the Add button while the
Delete button (Fig. 4.1) removes existing drawbead geometries.
Working with Drawbead generator

The following parameters from Drawbead generator have to be
used Drwbds page of the Input generator:
Drawbead generator Input generator
Shape Width w Width

Forces Restraining, if Force fac- Forcefactor
tor button is active
Since the Drawbead generator is currently a Beta–Version, the cal-

culated values for Width and Restraining have to be input manu-
ally in the Input generator. This will be done automatically in the
next version.
69
Lesson 5: Tipping and Cutting
2. 5 Lesson 5: Tipping and Cutting
This lesson describes tipping and cutting operations in AutoForm.
Fig. 5.1
Tool geometry of Lesson 5 with cutting lines
The drawing direction in AutoForm is always z–direction. The

geometry must be always checked for undercuts. If undercuts exist,
the geometry has to be tipped (using the Tip page) to find a good
drawing direction.
Preparation of Simulation
Open a new simulation:
File > New ... > File name: in_lesson_05 > OK
Geometry generator window is opened
File > Import ... > af > OK > in_lesson_05.af > OK
Drawing direction is modified from Tip page (Fig. 5.2).
70
Fig. 5.2
Tip page of Geometry generator
• Double attached: Various options to tip double attached

parts
• Define...: Definition of a new center of rotation for tipping
the part
Total Tipping • Average Normal: Uses normal vector of geometry as draw-
ing direction.
• Min draw depth: Calculates a drawing direction with min-
imum drawing depth.
• Min backdraft: Calculates a drawing direction with mini-
mum undercuts.
• Screen axes: Uses the normal of the display as drawing
direction.
71
• Set draw dir ...: Definition of drawing direction with two

points or one line
• Reference ...: The drawing direction of the active tool is
adapted to the drawing direction of a selected reference
tool (e.g. helpful for multistage process, to adapt the draw-
ing direction of the different stages).
• Sync: Mirrors drawing direction for double attached parts.
• Reset: Uses the original axis of CAD data (z–axis) as draw-
ing direction.
• Import ...: Reads in a rotation matrix.
• Export ...: Write out a rotation matrix in VDAFS–, IGES– or
AutoForm–format.
• Incremental tipping: Allows rotation by a specific angle
around x–, y– or z–axis or around a user defined axis.
• by degrees: Specific angle
• by dx dy dz: distance in x–,y– and z–direction, to move the
geometry.
• rotate +/-: Start rotation.
• move +/-: Start displacement.
• Backdraft diagram: All possible undercut–free drawing
directions are calculated (using Plot) and displayed in the
diagram.
If the center of the plot is completely within the green circle the
geometry is undercut free (default: Safe > 3°); if the center is
between green and red circles, geometry is in marginal area
(default: Marginal: 0° ~ 3°); if the center is outside the red circle,
geometry has undercuts (default: Severe: ≤ 0°).
This diagram helps to find an undercut free drawing direction:
• X-/Y-/Z-Axis: Shows the rotation matrix of the part.

• Current transformation: Real transformation (rotation
around x–,y– and z–axis and displacement at x–,y– and z–
direction)
72
Display > Backdrafts (Fig. 5.3).
Fig. 5.3
Tool geometry of Lesson 5 with undercuts
Display menu of Geometry generator with Backdrafts switched on
To find a good drawing direction it is recommended to use the

option Average normal and then rotate manually until an undercut
free drawing direction is found.
In this example we use the option named Min backdraft. Here the
geometry is rotated about the z–axis by +65 degrees to align the
geometry with the x–axis.
The current rotation (Tip page bottom) should read X = -71.58, Y = -

50.66, Z = 65 degree.
Fig. 5.4
73
Fig. 5.5
Tipped geometry
Definition of tools
Select faces of binder surface (right mouse button or Shift – right Prepare
mouse button for selecting multiple faces)
Define objects: Binder
Input generation
The title is already pre–defined. On Tools page Columns have to be

defined for the binder. It is recommended to use
Tool center
Complete input using tabs from left to right. Since it is a single

action process, use the following position values for the tools:
Tools > punch > Move: 0 >

binder > Move: 30 Columns > None >
die >Move: -530
74
Fig. 5.6
Position of tools
Blank The blank is first created in CAD and imported to AutoForm:
Blank > Import ... > af > Use all > Rotate > OK (Fig. 5.7)
Fig. 5.7
Dialog: Import line(s)
Select a file > In_lesson_05_crv.af > OK
File named in_lesson_05_crv.af contains all curves which are used

in this lesson (cutting lines, cutting directions, blank).
Select curve > Curve 1 > OK (Fig. 5.8).
75
Fig. 5.8
Dialog: Select curve with selected curve Curve 1
For a single action process, the blank has to be positioned on the

binder.
Position > On: binder Blank
Add a drawbead with a force factor of 0.35:
Add > Drawbead … > Use default settings > Add drawbead
Drwbds > Tools > Above: die > Below: binder
Drawbead line > Copy From … > Bndry (Pre) 1 > OK
Drawbead line > Edit … > Global mod > Expand: 20 > OK
Width: 15 > Forcefactor: Medium 0.35
Drwbds page should look like fig. 5.9.
76
Fig. 5.9
Drwbds page
The main display with punch and binder switched on should look
like fig. 5.10
Fig. 5.10
Punch and binder with blank and drawbead
77
Complete single action process definition on the Process page:
Gravity
gravity > Gravity: Downwards > Tool control: Show all >
die: Non-active
punch: Stationary
binder: Stationary (Fig. 5.11)
Fig. 5.11
Input for gravity
Binder wrap
During binder wrap phase, the die moves towards the binder, and
the binder and the punch are stationary.
closing > Tool control: die > Displcmnt > Velocity: 1 > Set >
punch: Stationary > binder: Stationary
78
Fig. 5.12
Input for binder wrap
Drawing
During the drawing phase, the die moves over the punch, the
binder is force–controlled and is displaced by the die, while the
punch is stationary.
drawing > Tool control: die > Displcmnt > Velocity: 1 > Set >
punch: Stationary > binder > Force > Relative tool: > die > Const
pressure > Value: 3 > Set
79
Fig. 5.13
Input for drawing
Definition of different cutting process types

The definition of cutting processes is always done on Process page
of the Input generator. In AutoForm different cutting types can be
defined:
• Relief cut
• Trimming cut
• Hole
Definition of a relief cut 5 mm before bottom down

The following steps have to be defined:
• Drawing process (existing process drawing) must be

stopped 5mm before bottom down.
• Cutting line for relief cut must be defined.
• Drawing process must continue until bottom down.
80
Stop drawing process 5mm before bottom down

Select process step drawing on Process page. Duration of drawing
is 30. This value must be changed to stop the process 5mm before
bottom down.
drawing > Duration > During time > Time: 25
Change the name of this process step:
drawing > Name: drawing1 (Fig. 5.14)
Fig. 5.14
Drawing until 5mm before bottom down
81
Definition of a relief cut

A new process step has to be added to define a relief cut.
Add process step ... > Cutting > Insert position: Insert after >
drawing1 > Add process step
On Process page a new subpage is created (Fig. 5.15), which must

be completed:
Fig. 5.15
Input for definition of relief cut
Process step > Name: cutting1 > Cut 2D >

Cut Contour: Copy from … > Select curve > Curve 4 > OK >
Cutting type: Open cut
82
The geometry (punch and binder switched on) should look like fig.
5.16.
Fig. 5.16
Punch and binder with defined relief cut
Finishing deep drawing process (last 5 mm)

Now the deep drawing process must be completed (last 5 mm). A
new process step has to be added again:
Add process step ... > Forming > Insert position: Insert after >
cutting1 > Add process step (Fig. 5.17)
Fig. 5.17
Add a new process step to finish deep drawing process
Process step > Name: drawing2 > Type: drawing
83
Tool control: Tool movement remain unchanged.
Fig. 5.18
Input of process step to finish deep drawing process
Definition of trimming cut

A new process step has to be added as last process step for the defi-
nition of a trimming cut. The cutline curve is taken from the file
in_lesson_05_crv.af.
Add process step ... > Cutting > Insert position > Insert after >
drawing2 > Add process step
Name: cutting2 > Cut 2D > Cut contour > Copy from ... > Select
curve > select curve in main display (Curve 1) with right mouse
button (Fig. 5.19)
> Select curve > OK
84
Fig. 5.19
Cut line for trimming cut
Cutting type > Trimming cut (Fig. 5.20)
For Trimming cut all elements outside the cutline will be deleted.
Fig. 5.20
Input for trimming cut

85
Definition of two holes with cutting direction not

along z–axis
Finally, two holes with different cutting directions should be
defined. The cutting lines as well as the vectors to determine the
cutting directions have already been imported from the file
in_lesson_05_crv.af.
New process steps have to be added:
cutting2 > Add process step
Process step > Name: cutting3 > Cut 2D > Copy from ... > Select
curve > select curve in main display (Curve 2) with right mouse
button (Fig. 5.21)
> Select curve > OK
Fig. 5.21
Defined cut line for first hole
Cutting type > Hole
For Hole all elements inside the cut line will be deleted.
Use a line to define the cutting direction:
cutting3 > Cutting direction > Copy f. … > Select curve > Curve 3 >
OK (Fig. 5.22) > Keep
86
Fig. 5.22
Cutting direction for first hole
87
Fig. 5.23
Input for first hole
Do the same for the definition of the second hole:
cutting3 > Add process step
Process step > Name: cutting4 > Cut 2D > Select curve > select
curve in main display (Curve 3) with right mouse button (Fig.
5.24)
> Select curve > OK
88
Fig. 5.24
Defined cut line for second hole
Cutting type > Hole
Cutting4 > Cutting direction > Copy f. … > Select curve > Curve 2 >
OK > Replace > Keep (Fig. 5.25)
Fig. 5.25
Cutting direction for second hole
89
Fig. 5.26
Input for second hole
Input is completed.

90
Lesson 6: Optimization
2. 6 Lesson 6: Optimization
This lesson describes in a simple example how process parameters can be automati-
cally optimized using AutoForm’s optimization algorithm. The process parameters can
be binder forces or drawbead force factors.
Fig. 6.1
Punch, binder and drawbeads of the optimization example
AutoForm offers an optimization algorithm that is fully integrated

into the user interface. It allows the user to optimize various input
parameters, so that a robust and high–quality part can be produced
consistently. Optimization criteria can be defined by the user by
using the different FLD zones. In most cases, the criteria will be
used to produce a part without any cracks/splits and wrinkles, and
having a uniform thickness strain (e.g. 2%) in all areas. Input
parameters, which are available for an optimization can be binder
forces, drawbead force factors, blank size or tool geometry (using
AutoForm–DieDesigner). For all these optimization parameters, the
user defines (a) the parameters and (b) the allowable minimum and
maximum values of these parameters. Selected optimization param-
eters are marked in the Input and Geometry generator in yellow
(highlighted).
Parameter studies are also possible with AutoForm–Optimizer.

Input parameters can be automatically varied and the result varia-
tions can be analyzed to determine the process sensitivity and
dependence on the parameters. The goal is to find the dependency
of the results of the drawing process on the parameters and to
determine a process window.
91
In the following example, an optimization is defined for the draw-

bead forces of three drawbeads for an incremental simulation
(geometry from Lesson 5) of a single action press.
Open simulation file in_lesson_06_basis.sim:
File > Open > in_lesson_06_basis.sim > OK
Create an optimization:
Model > Input generator … > Create > Optimization
First the design variables have to be defined, and these will then be
varied automatically by the optimization algorithm to achieve bet-
ter quality of the draw part. Drawbead Force factors of beads
bead1, bead2 and bead3 will be optimized. This process is setup as
follows:
Drwbds > bead1 > Forcefactor
Click with right mouse button on the yellow framed input field of
the drawbead force factor. A menu titled Add/edit design variable
is opened (Fig. 6.2).
Fig. 6.2
Menu to define design variable
92
• Name: Name of design variable

• Dependent: Name of a previously defined design variable:
This defines a dependent design variable, which means the
value of this parameter depends on the previous one.
• Independent: Definition of a fully independent design
variable
• Start: Starting value of design variable to use
• Min: Minimum allowable value of design variable
• Max: Maximum allowable value of design variable
The optimization range of all three drawbeads is between „no

drawbead“ (Forcefactor = 0.0) and lock bead (Forcefactor = 2.0). The
starting value for each drawbead is „no drawbead“ (Forcefactor =
0.0). All three drawbeads will have the same geometry. This means
only one independent parameter needs to be used. The other two
design variables will depend on the first one. This reduces calcula-
tion time for this example. In reality all three design variables
would be treated as independent.
Complete the input for the force factor of the first drawbead (design
variable) in the menu Design variable definition of the menu Add/
edit design variable as follows:
Name: db > Dependent: Independent > Start: 0 > Min: 0 > Max: 2
(Fig. 6.2) > OK
Now the background color of input field has changed to yellow.

This means the parameter is to be used as a design variable. The
name of this variable is displayed in the input field (Fig. 6.3).
93
Fig. 6.3
Menu to define bead1 – Forcefactor is defined as db
Repeat the same steps for bead2, which should be defined as being
dependent on bead1 (design variable db). Use the following input:
Input generator > Drwbds > bead2 > Forcefactor
Name: db2 > Dependent: db > Min: 0 > Max: 2 (Fig. 6.2) > OK
The input field Start: has no value, because it is a dependent design

variable. The background color of this input field has changed to
yellow. The name of the design variable is displayed in the input
field (Fig. 6.4).
94
Fig. 6.4
Menu to define bead2 – Forcefactor is defined as db2
Repeat for bead3:
Input generator > Drwbds > bead2 > Forcefactor
Name: db3 > Dependent: db > Min: 0 > Max: 2 (see Fig. 6.2) > OK
As seen above, the input field Start: has no value, because it is also a
dependent design variable. The background color of this input field
has changed to yellow. The name of this variable is displayed in the
input field (Fig. 6.5).
95
Fig. 6.5
Menu to define bead3 – Forcefactor is defined as db3
All design variables have been defined now. Complete the input on
Optimize–page in the Input generator. Switch to this page (Fig. 6.6).
96
Fig. 6.6
Optimize – Design v. page of Input generator
Design variables • Optimization/Parameter study: Definition of optimization

or parameter study
• Optimization: Optimization will be performed.
• Normal random: Parameter study; variables will have a
Gaussian distribution around a defined center in parame-
ter range.
• Uniform random: Parameter study; variables will have an
arbitrary distribution in parameter range.
• Regular grid: Parameter study; variables will have a regu-
lar distribution in parameter range with a specified num-
ber of calculations.
• Name: Name of design variable
• Current: Current value of design variable for the opened
simulation file
• Start: Start value of design variable
• Min: Minimum value of design variable
• Max: Maximum value of design variable
97
Switch to sub page Optimize – Control (Fig. 6.7):
Fig. 6.7
Optimize – Control page of the Input generator
• Maximum number of simulations: Maximum number of Iteration control

simulations for an optimization or parameter study. The
study will be stopped if the maximum number of iterations
is reached.
• Accuracy: If variation of target function is smaller than the
Accuracy value. Optimization/parameter study will be
stopped (convergence has been reached).
• All: All simulations are stored on disk (warning: this Keep simulations
requires a large amount of disk space).
• Series of best: The next best simulation is always stored on
disk.
• Only best: Only the best simulation is stored on disk.
• None: No simulation is stored on disk.
98
Hosts User can specify a list of computers which can be used for optimiza-
tion/parameter study:
• Name: Name of computer

• Directory: Directory in which simulations can be stored
temporarily.
• #Lic: Number of AutoForm Licenses on computer
• #Jobs: Number of jobs, which can run in parallel
• Use: Use or do not use this computer for this optimization/
parameter study.
• Add host …: Specify a new computer for optimization/
parameter study.
• Edit host …: Edit computer parameters for optimization/
parameter study.
• Save hosts: Save specified parameters of computers.
No inputs are necessary on Control–page for this example. By

default, the local computer is selected and activated for usage for
optimization/parameter study. The directory in which simulations
are stored is the directory from which the AutoForm user–interface
was launched or from which the simulation file was opened. Click
on the host name on Control page. Now open the menu named
Add/edit hosts by clicking the button Edit host ... (Fig. 6.8):
Fig. 6.8
Add/edit host
host–menu on Control page of optimizer
99
• Hostname: Name of computers Host definition

• Get possible executables from host: Search for available
AutoForm solvers. Solvers are displayed in the Incremen-
tal and Onestep fields.
• Working directory: Directory in which the simulation file
is stored.
• Remote shell: Type of shell
• Remote copy: Remote copy command
• Names of executables: Names of AutoForm solvers
• Incremental: AutoForm–Incremental solver
• # Incremental licenses: Number of AutoForm–Incremental
solver licenses
• Onestep: AutoForm–Onestep solver
• # Onestep licenses: Number of AutoForm–Onestep solver
licenses
• OK: OK
• Cancel: Cancel
Close this menu using Cancel. Switch to the Target page (Fig. 6.9).
The target function is defined for two regions:
• No cracks are allowed for the whole part.

• A minimum thinning of 2% is requested for the punch
area.
• These two areas (whole part – Target and punch – Target1)
are defined in AutoForm by default. Only the following
inputs have to be changed on pages Target and Target1 of
the Optimize page in Input generator:
Target > Global target function > Cracks > Limit % FLC: -20
All other target values (Excessive thinning, Wrinkles, Insuff.

Stretching, Desired strain) should be deactivated (Fig. 6.9).
100
Fig. 6.9
Target page of Optimizer
• Cracks – Limit % FLC: Target area – Percentage above (+)

or below (-) the FLD
• Excessive thinning – Acceptable thinning: Maximum
acceptable thinning
• Wrinkles – Acceptable thickening: Maximum acceptable
thickening for wrinkles
• Insuff. Stretching – Required thinning: Required thinning
• Desired strain – Desired major=minor strain: Desired
plastic strain
Target1 > Local target function > Cracks > Limit % FLC: -20 >
Insuff. stretching > Required thinning: 0.02
All other target values (Excessive thinning, Wrinkles, Desired

strain) should be deactivated (Fig. 6.10).
101
Fig. 6.10
Target1 page of optimizer
Save the optimization input in file in_lesson_06.opt using the fol-

lowing options:
File > Save as … > in_lesson_06.opt > OK
Start the optimization using:
Run > Start Optimization … > Program: afopt_3.1 > Start (Fig. 6.11)
102
Fig. 6.11
Optimization manager page
File • Save as plain simulation …: Save as simulation without

optimization.
• Fork to new optimization ...: Save as a base simulation file
for new optimization.
• Delete simulations …: Delete the stored simulation files
(user–selected).
• Strip optimization: Delete all simulation files except base
simulation file.
Buttons • Program: Choice of optimizer version

• Start: Start optimization
• Open sim.: Opens a stored simulation file from an optimi-
zation run.
• Base: Choice of stored simulation files from an optimiza-
tion run
• Convergence …: Display of convergence of the optimiza-
tion run.
• Delete sim …: Delete stored simulation files (user–
selected).
• Dismiss: Close the Optimization manager menu
103
Analyze optimization results

When all simulations of the optimization run have been completed,
open the simulation file using:
File > Open optimization ... > in_lesson_06.opt > OK
First open the menu titled Start/manage optimization ... using:
Run > Start/manage optimization ... (Fig. 6.12)
Fig. 6.12
Optimization manager page is opened when optimization run is

finished
Use the Convergence ... menu to get a first overview about the
number of simulations, behavior of convergence, and the best simu-
lation result. Open the Convergence ... menu using:
Run > Start/manage optimization ... > Convergence ...
The target function value is displayed over the number of simula-

tions (Fig. 6.13).
104
Fig. 6.13
Menu Convergence with activated option Target
Stored simulations are marked with a bullet, and the best simula-
tion (31st) with a rectangle. Switch to option All criteria (Fig. 6.14).
The target function is now divided into single criteria, displayed
over the number of simulations in the optimization run. The differ-
ent criteria of the target function are:
• Wrinkles/Insufficient stretching
• Desired strain
• Cracks/Excessive thinning
It can be seen that cracks are the reason for peaks in the target func-
tion (Fig. 6.14).
105
Fig. 6.14
Menu Convergence with activated option All criteria
Switch to the option Log(Target) (Fig. 6.15). The target function

value is now displayed in logarithmic form over the number of sim-
ulations in the optimization run.
Fig. 6.15
Menu Convergence with activated option Log(target)
106
Open the first simulation of optimization using:
Run > Start/manage optimization ... > Open sim.: 1 > Yes (Fig. 6.16)
Fig. 6.16
Optimization manager page with simulation 1 open
Use Ctrl – E to go to the simulation end and switch on the Form-

ability result variable. It can be seen that insufficient stretching
occurs in large areas of the part.
Switch on the display of all lines in AutoForm’s main menu area:
Display > Lines ... > Lines: Show all > Dismiss or use hotkey Ctrl –
L to open Lines menu.
Click with the right mouse button on the three drawbeads (design–
variables) which should be optimized to get the current force factors
(Fig. 6.17).
107
Fig. 6.17
Simulation 1 of optimization run with result variable Formability and

drawbeads with force factors
Now open the best (# 31) simulation of the optimization run using:
Run > Start/manage optimization ... > Open sim.: 31 > Yes (Fig.
6.18)
Fig. 6.18
Optimization manager page with simulation 31 open
108
Use Ctrl – E to go to the end of the simulation and switch on the

Formability result variable. It can be seen that the part is much
more uniformly stretched.
Switch on the display of all lines:
Display > Lines ... > Lines: Show all > Dismiss or use hotkey Ctrl –
L to open Lines
Click with the right mouse button on the three drawbeads which
should be optimized to get the current force factors (Fig. 6.19).
Fig. 6.19
Simulation 31 of optimization run with result variable Formability and

drawbeads with force factors

109
Lesson 7: Automatic Filleting with a Constant Radius
2. 7 Lesson 7: Automatic Filleting with a Constant Radius
The functions described in this lesson are used in the preparation of the simulation
data.
At the beginning of each simulation the geometry of the meshed CAD tool data
should be checked for sharp edges. In case there are any sharp edges AutoForm–
Incremental can automatically fillet these with a global radius.
Warning:
Warning Sharp edges that are not filleted during the preparation of
a simulation may lead to faulty results (unrealistic cracks).
Global filleting of sharp edges

The procedure of checking and filleting are presented through fol-
lowing simple example. (Fig. 7.1).
Fig. 7.1
Geometry
First the geometry in VDAFS format is read in and meshed:
110
File > Import ... > VDAFS > OK > in_lesson_07.vda > OK >
Checking of sharp edges and filleting if necessary is done in the

geometry editor on the Fillet page (Fig. 7.2).
Fig. 7.2
Fillet page in the Geometry generator
• Check: Checks geometry with the Check radius (e.g. 2

mm).
• OK: Accepts the result.
• Global radius: Value of the global filleting radius (default
value: 3 mm). This button becomes active only after press-
ing OK.
• Apply: Fillets all edges with the Global radius value.
• Filleted geometry: Displays filleted geometry (Fig. 7.3).
• Edged geometry: Displays edged geometry with the
located sharp edges (Fig. 7.4).
All of the above mentioned buttons will become active only after
selecting Apply.
111
Fig. 7.3
Filleted geometry (Partial view)
Fig. 7.4
Edged geometry with the located sharp edges (Partial view)
In combination with AutoForm DieDesigner there is an additional

function to create local fillets on selected edges of the meshed part
geometry. This can be either done with a constant or a variable
radius.
112
After using the Fillet function in AutoForm the preparation of the

simulation continues as already described in the previous lessons.
Opening the Input Generator AutoForm automatically uses the fil-
leted geometry of the tools.
Use of the filleted or edged geometry

As already described the Input Generator automatically takes the
filleted geometry of the die, punch and binder. However, AutoForm
retains the original edged geometry in memory. It is possible to tog-
gle between the edged and the filleted geometry at any time. This
can be done on the Tools page in the Input Generator.
Go to Tools page:
Geometry > Reference....
The window titled Reference tool geometry will be opened. Using

Options (Fig. 7.5) you can choose between the edged and the fil-
leted geometry:
• edged: Use original faces

• filleted: Use processed faces (Fig. 7.5).
Fig. 7.5
Window: Reference tool geometry
In this window you may choose whether the edged or the filleted
geometry should be used for the definition of tools.
113
Definition of tools with automatically filleted die

radius
In case sharp edges between the binder and addendum are found
and automatically filleted, this area is treated by AutoForm Incre-
mental in a special way.
During the automatic filleting in AutoForm Incremental a radius is

generated at both adjoining faces. The binder receives half of the fil-
let radius and therefore that the binder surface is modified (see Fig.
7.6 red elements, binder is no longer flat).
Fig. 7.6
Faces after automatic filleting
In order to avoid this problem, the following procedure should be

followed:
• Load the tool geometry,

• define binder surface,
• check for sharp edges and fillet.
• AutoForm then generates the die and punch using the fil-
leted geometry and the binder using the edged geometry
These steps are described in detail in the following sections. For this
purpose, the example in_lesson_07.vda is used, which should
114
already have been imported and meshed. Starting from this point
the preparation steps of the simulation will be described.
Define binder
By defining the binder surface the tool geometry is divided auto-
matically in die, punch, and binder. The corresponding faces can be
selected on the main using Shift and the right mouse button (Fig.
7.7).
Fig. 7.7
Selected faces describing the binder
Prepare Define objects: Binder
Check geometry for sharp edges and automatic filleting

Change to the Fillet page in the Geometry generator and check the
geometry for sharp edges (Check radius value = 2 mm).
Fillet Check radius: 2.00 > Check > OK
Some sharp edges have been found. They are shown in Fig. 7.4 in
blue.
Now, fillet these sharp edges with a global radius of 12 mm.
115
Global radius: 12.00 > Apply
The resulting filleted geometry is shown in Fig. 7.3.
Open the Input generator. In Fig. 7.8 you can see the tools, which
have been defined automatically.
Fig. 7.8
New tool geometries (die and punch with filleted edges, binder
with sharp edges)
Completing the Input generator

The Input generator still has to be completed in this example in the
same way as in the previous lessons:
The positioning of the tools should be changed to a single action Tools

process:
die > Move: -600

punch > Move: 0
binder > Move: 100
binder > Columns: Tool center
Here the blank is defined as an arc segment. This is carried out with Blank
the following commands:
116
Outline > Arc ... > Center x, y: 0, 0 > Radius: 270 > Angles > Start: 0
> End: 90 > OK (Fig. 7.9)
Fig. 7.9
Definition of the blank as a circular segment
The fields Center and Radius define center and radius of the circle.
To define a circular blank this information is sufficient. In this exam-
ple the tools are symmetrical, therefore only one quarter of the cir-
cular blank is required. The first quarter of the defined circle is
used. This is defined with the values Start 0 and End 90.
In addition, the symmetry planes for the blank have to be defined.

This is carried out in the lower half of the Blank page:
Add symmetry ... > Symmetry-plane at start side > OK (Fig. 7.10)
Add symmetry ... > Symmetry-plane at end side > OK
Fig. 7.10
Window for definition of the symmetry planes if the blank is a seg-

ment of a circle
Due to the definition of the blank as a segment instead of being

defined by nodes, the symmetry plane cannot be chosen by clicking
on one side of the blank as shown in previous examples. In these
cases the start and/or end side can be defined as the symmetry
plane (see Fig. 7.10).
117
An additional input which has to be provided, is the initial location

of the blank. On the Tool page the single action process was already
taken into consideration. This means that the blank is positioned on
the binder. This has to be defined on the Blank page. As a default
the blank is placed on the die (see Blank page> Position > On: die).
This button has to be changed to binder (Fig. 7.11).
Fig. 7.11
Detail Blank page: At the beginning of the forming process the

blank lies on the binder
On this page the process is defined. In this example, the punch is Process
located on the press bed, and during the forming process the die
moves and pushes the binder downwards. The following tool
movements explain every single process step:
gravity > Downwards

die: Non-active
punch: Stationary
binder: Stationary
closing > Type: Binder wrap

Tool control > Show all
die > Displcmnt > Velocity: 1 > Set
punch: Stationary
binder: Stationary
Duration > During time > Time: 500
drawing > Type: Drawing

die: Displcmnt > Velocity: 1 > Set
punch: Stationary
binder: Force > Relative tool: die > Const pressure > Value: 3 > Set
In the lower half of the Control page there is the WriteRestart but- Control
ton. This button selects whether an additional Restart file (*.rst)
should be generated during simulation. This file contains all infor-
118
mation necessary to later continue the simulation in a separate

example.
For this case the button WriteRestart should be activated.
WriteRestart > On
Advanced … > RestartTimeStep: Auto (Fig. 7.12)
Fig. 7.12
Window to define Restart Time Steps
Next to this button, there is another button called Advanced ….

Clicking the Advanced ... button opens a window (Fig. 7.12), where
you can define the intervals of the information written to the Restart
File (RestartTimeStep). If Auto is selected (see Fig. 7.12) informa-
tion at the end of each process step is written to the restart file (end
of gravity, binder wrap and drawing). This means that the new sim-
ulation can only be re–started at the end of one of those process
steps.
If a different value is given (e.g. 10) the information is saved to the

restart file after ever 10 time steps. If for example one process step
such as drawing takes 100 seconds (see Process page > Duration)
the information is written to the Restart file a total of 10 times. This
causes the size of the Restart file to be substantially larger and the
calculation takes longer (as writing the Restart file takes more time).
However a new simulation could be re–started at any 10 second
interval. The appropriate settings have to be estimated by the user.
Start of the Simulation

Job > Start simulation ... > Kinematic check only > Start
With kinematic check the tool movement can be controlled. If every-

thing is defined correctly the simulation can be carried out without
this option (Kinematic check only – off).
119
Lesson 8: Multiple Step Process and Starting from Restart File
2. 8 Lesson 8: Multiple Step Process and Starting from

Restart File
AutoForm–Incremental allows simulation of deep drawing processes that consist of sev-

eral process steps (e.g. multi–stage processing). CAD data is required for every process
step and each set of tools. The preparation of such Input will be explained using the
example from Lesson 7 (Automatic filleting with a constant radius and starting of a sim-
ulation with the Restart file). The part is drawn in two drawing steps (Fig. 8.1).
Fig. 8.1
Example in_lesson_08
In this case there are two possible approaches:
• Either the entire process (i.e., both steps) is defined in a sin-

gle simulation file. In comparison to a standard simulation,
the tools (die, punch, binder, etc.) for both drawing steps
and for the complete process have to be defined. As a
result, the AutoForm simulation file contains result from
both drawing steps.
• Or the first drawing process is simulated (when, for exam-
ple, only the tools for the first drawing step are available).
In this case, during the simulation, a restart file can be
generated. In this Restart File all necessary information is
saved in order to continue the drawing process using a
separate simulation. This means the second step will be
carried out at the end of the first drawing operation as a
separate simulation.
120
Starting a simulation using a Restart File

In Lesson 7, the WriteRestart button in the Input generator on the
Control page was activated. This implies that during the calculation
of this example, a restart file (*.rst) has been generated. In the fol-
lowing, the second drawing process step will be prepared for a sep-
arate simulation.
As the first step, the results of Lesson 7 have to be read in. There are
two ways of doing this:
• Open *.sim file or

• Open *.rst file.
Proceed as follows. Open the *.sim file:
File > Open ... > in_lesson_07.sim > OK
The information from both files in_lesson_07.sim and

in_lesson_07.rst are loaded. Therefore, the results of the first draw-
ing step can be viewed while preparing the new simulation for the
second step.
After opening the sim files the results of the first drawing step are
shown. In order to define the input for the second drawing step, the
Input generator should be opened with the command:
Model > Input generator ...
Open the *.rst File:
File > Open restart ... > in_lesson_07.rst > OK
Only the information from file in_lesson_07.rst is loaded into the

Input generator. The results are not visible. In this case, the Input
generator opens automatically. No results are seen on the main
screen.
The Input generator

After opening both files, all information about the first drawing step
are available in the Input generator, independently from opening
either the *.sim or *.rst files. In contrast to a standard simulation the
Title page has also been changed (Fig. 8.2).
121
Fig. 8.2
Title page in the Input generator after opening a *.rst file
The upper half of the Title page is as before. In the lower half, there
is the necessary information to define a subsequent simulation in a
separate calculation.
• Job info: Contains general information about the first sim-

ulation (date, user, hostname, jobname, directory).
• Restart times: These are all process steps and time steps
written to the *.rst file. In Lesson 7, the end of each process
step was saved to the restart file. Hence in Fig. 8.2 it can be
seen that time steps 0, 500, and 600 are shown correspond-
ing to the process steps gravity, closing and drawing. Thus
a new simulation can be created after each time step.
For this the button Make restart (next to the desired time step) has
to be clicked. All the restart options for this example will be
explained below. After this, you may continue with the section
titled Start of the current example from sim file.
122
Make restart after gravity process step

If you wish to define a new simulation and just use the previous
gravity results, press the button
Make restart
Make restart after the process step gravity

Now a new *.sim File named in_lesson_07_r1.sim will be created.
In addition a new subpage (Rst1) opens. You can switch between
both subpages (Rst1 and Base) on the Title page (Fig. 8.3).
Fig. 8.3
Detail of the Title page after pressing the Make restart button –
switching between both Input generators is possible
In the new Input generator all information used in the gravity pro-
cess step are grayed out (cannot be changed) (Fig. 8.4 – 8.8).
Fig. 8.4
Detail Tool page for the new simulation, only the die can be modi-
fied.
123
Fig. 8.5
Blank page of the new simulation – the blank cannot be modified
Fig. 8.6
Lube page of the new simulation
124
The friction can only be modified with respect to the die. If a Con-
stant friction had been selected instead of Table, friction cannot be
modified.
Fig. 8.7
Detail of the Process page for the new simulation – process steps
closing and drawing can be changed.
Fig. 8.8
Detail of the Control page of the new simulation – both Binder wrap
and Bending effects cannot be modified any more.
Saving of data
File > Save
In case you would like to define another simulation for a different

time step you have to read in the base simulation in_lesson_07.sim
or in_lesson_07.rst.
125
Make restart after closing

If you wish to define a new simulation using only the previous
results of gravity and binder wrap press the button titled
Make restart after the process step closing.

Note:
Note A new *.sim file is created named in_lesson_07_r1.sim.
in_lesson_07_r1.sim You
have to rename this file before in order to avoid overwriting the pre-
vious restart file.
In addition to the sim file, new input will also be generated. Again,
it is possible to change only those values that have not been used
previously in the gravity and closing process steps.
• Tools: None of the tools can be changed.

• Blank: Blank cannot be modified.
• Lube: The friction cannot be modified for any of the tools.
• Process: The Duration of the process step closing can be
changed, as this process step can be continued if desired.
Also the process step drawing can be modified.
• Control: Binder wrap and Bending effects cannot be
changed any more.
In addition to these allowable changes, new tools and process steps

can be defined. This will be treated later in this lesson.
Make restart after the process step drawing

If you wish to define a new simulation using the previous results of
the first drawing step press the button titled
Make restart after the process step drawing.
Note:
Note A new *.sim file is generated named in_lesson_07_r1.sim.
in_lesson_07_r1.sim
You have to rename the file before in order to avoid overwriting the
previous restart file.
Again, it is possible to change only those values that have not been
used in any of the previous process steps.
• Tools: None of the tools can be changed.

• Blank: Blank cannot be modified.
• Lube: The friction cannot be modified for any of the tools.
• Process: The Duration of the process step drawing can be
changed, as this process step can be continued if desired.
126
• Control: Binder wrap and Bending effects cannot be

changed any more.
Apart from the allowed changes new tools and process steps can be
defined. This will be treated later in this lesson.
On the lower part of the Title page there is an additional button:

Recalculate all (see Fig. 8.2).
This button is used if several simulation from the restart have been
carried out. In order to create a single simulation file of all calcula-
tions – e.g. for better organization of the results file. With this but-
ton the complete simulation can be recalculated.
Start of the current example from the sim file

Open the simulation file from Lesson 7:
File > Open … > in_lesson_07.sim > OK
Model > Input generator …
After the process step drawing > Make restart
File > Save as ... > in_lesson_08.sim > OK
Now a new Input generator is opened. In the following the second

drawing step for this forming operation has to be defined. Tools and
process are defined as in the previous lessons.
Definition of a multiple step process

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,
• sharp edges and
• undercuts.
Prepare Apply
127
As there is only a single free boundary, the outline is automatically

defined. (Fig. 8.9).
Fig. 8.9
Determination of free boundaries
Check for sharp edges
Check radius: 2.00 > Check > OK Fillet
No sharp edges have been found (Fig. 8.10).
128
Fig. 8.10
Checks for sharp edges
Tip > geometry is green (Fig. 8.11) which means there are no under-
cuts
129
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
Selected faces describe the binder for the second drawing step
130
Prepare > Define objects: Binder > Apply
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 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
Dialog to introduce a new window on the Tools page for die2
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).
131
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
Window to define geometry of die2
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).
132
Fig. 8.15
Input for die2
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
Dialog for the insertion of a new window on the Tools page for
punch2
133
Name: punch2

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
Tools page – Input for punch2
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.
134
Add tool ... > Use settings of tool: punch2 > Add tool
Tools Name: binder2

Select objects > Binder > OK
The following is the entry for tool binder2 in the Input generator
(Fig. 8.18).
Fig. 8.18
Tools page – Input for binder2
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.
135
The blank has already been defined for the first drawing step in Les- Definition of the
son 7. The calculation continues with the partially finished part. No Blank
new entries are necessary.
Friction can only be defined for the tools of the second drawing step Friction (Lube)
(Fig. 8.19).
Fig. 8.19
Definition of the friction coefficient for the tools in the second step
On the Process page all steps except drawing are grayed out. It is Process
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
136
Positioning of the In order to position the partially finished part on the tool of the sec-
part 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:
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)
137
Fig. 8.21
Detail Process 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 process steps (as in reality and also in
the previous lessons).
Add process step ... > Forming > Use settings of forming step: > Closing of
drawing > Insert position: Insert after > positioning1 > Add pro- binder
cess step
Name: closing2 (Fig. 8.22) Process

Type: Restrike
die: Non-active
punch: Non-active
binder: Non-active
die2: Stationary
punch2: Non-active
binder2: Displcmnt > Velocity: 1 > Set
138
Fig. 8.22
Process page: Input for the closing of the binder during the second
forming operation
Caution In defining the 2nd operation it is important to select

Caution:
Restrike as the drawing type (Fig. 8.22).
Second opera- Add process step ... > Forming > Use settings of forming step:
tion closing2 > Insert position: Insert after > closing2 > Add process
step
Process Name: drawing2

Type: Restrike
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 >
139
Set
Fig. 8.23
Process page: Input for the 2nd drawing step
Caution In defining the 2nd operation it is important to select

Caution:
Restrike as the drawing type (Fig. 8.23).
WriteRestart > OFF Control
Job > Start
140
Lesson 9: Using CAM Tools
2. 9 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
Preparation of tool geometry

Create a new simulation file:
Import and mesh tool geometry:
File > Import > IGES > OK > in_lesson_09.igs > OK > Program:
afmesh_3.1 > OK (Fig. 9.2)
141
Fig. 9.2
Imported geometry
Check geometry for free boundaries:
Apply Prepare
Free boundaries are displayed in blue color on the main display.
Check radius: 2.00 > Check Fillet
Message appears in log–window that no sharp edges have been

found.
Close window with the Dismiss command.
When activating the Tip page undercuts are immediately calculated Tip
for the active geometry and displayed in different colors on the
main screen (Fig. 9.3).
142
Fig. 9.3
Result of checking geometry for undercuts
Undercut areas in Fig. 9.3 are shown in red. The major part of the
geometry is undercut free (green area). However, the area of the
depression has undercuts (Fig. 9.4).
For this geometry it is not possible to find a tipping position which

has no undercuts. In this case a CAM tool has to be used.
Fig. 9.4
Undercut area
143
As the last step, the geometry has to be divided into die, punch and
binder.
Select faces of the binder (right mouse button or shift – right Prepare
mouse button to select several faces, Fig. 9.5)
Define objects: Binder
Now the geometry is divided into die, punch, and binder. We have
already generated the part boundary. Using the button
Generate part boundary: Apply
the generation of the part boundary starts and this boundary is dis-
played in blue.
Fig. 9.5
Selected binder face
Input generation for simulation

Open Input generator:
Model > Input generator ... > Simulation type: Incremental > Sheet
thickness: 1 > Geometry refers to: punch side > OK
On the Tools page, three tools have already been defined – die, Tools
punch and binder (Fig. 9.6).
144
Fig. 9.6
Automatically defined tools by AutoForm
The positioning of the tool corresponds to a double action drawing

process as the default in AutoForm. In this case we would like to
define a single action process. Therefore the following changes have
to be made:
• The die is mounted on the ram: Move: -532 (Fig. 9.7)

• The punch is mounted on the press bed: Move: 0 (Fig. 9.8)
• The binder is positioned with respect to the punch (lifted):
Move: 32 (Fig. 9.9)
Fig. 9.7
Detail Tools page: Position of the die
Fig. 9.8
Detail Tools page: Position of the punch
145
Fig. 9.9
Detail Tools page: Position of the binder
On this page, the binder is still marked in red, as the columns have
to be defined. It is recommended to use Tool center for this binder:
Columns > Tool center
Punch and binder can be used in this simulation as they are. From
the die, the depression has to be removed and defined as a separate
tool, i.e., the pad.
die > Geometry > Reference ... > Current geometry > 1 Tools
in_lesson_09 > Pick faces > Select with the right mouse button and
shift the faces of the depression (Fig. 9.10) > Deactivate > OK
Fig. 9.10
The selected faces describe the cam tool and are removed from
the die
In the next step, we can define the geometry for the cam. In order to
do so, a new window has been added to the tools page (Fig. 9.11
lower left).
Add tool ... > Use settings of tool: die > Add tool (Fig. 9.12)
146
Fig. 9.11
Add Tool... button
Fig. 9.12
Window: Add Tool...
Now the inputs in this new window have to be completed (Fig.

9.13):
147
Fig. 9.13
Tools page for the cam tool
Name: cam
As a reference for the cam tool the die had been used, therefore the
positioning (above) and the offset (1) are already defined correctly.
Geometry > Reference ... > Current geometry > 1 in_lesson_09 >
Pick faces > Select with the right mouse button and shift the faces
of the depression > Deactivate > Toggle active > OK (Fig. 9.14)
148
Fig. 9.14
Cam geometry
Import and mesh of the curves from CAD file for the working direc-
tion
The working direction of the cam tool is not parallel to the z–axis
and has to be taken from the CAD file. This has to be done with the
command:
Model > Curve manager ... > File > Import ... > IGES >
in_lesson_09_workdir.igs > OK > Program: afmesh_3.1 > OK (Fig.
9.15)
On the main display:
Ctrl – Y: to see geometry from Y–direction.
149
Fig. 9.15
Imports curve on the main screen
Working direction > Copy f. ... > Select curve (The dialog opens
automatically and all curves imported from the CAD file are dis-
played) > Curve 1 > OK > Replace
A red arrow for the working direction appears in the main display
(Fig. 9.16) and also the Question dialog window (Fig. 9.17), which
confirms if this direction should be kept.
Fig. 9.16
AutoForm suggested working direction for the CAM tool
Fig. 9.17
Query if suggested working direction should be kept or reversed.
Keep (the working direction with the suggested orientation is taken

into the Input).
Finally the CAM tool has to be positioned.
Working direction > Move: -40

150
Now all entries for the Cam tool are defined. (Fig. 9.13)
Blank The outer boundary of the blank is defined in AutoForm.
In the AutoForm user interface:
punch and binder > display (Fig. 9.18)

geometry > turn off (Fig. 9.18)
Ctrl – Z: to show geometry from z–direction.
Switch to show/hide geometry and tools
On the Blank page of the Input generator:
Outline > Copy from ... > Select curve > Bndry (Pre) 1 > OK
Outline > Edit ... > Curve editor > Global mod > Expand: 25 > Con-
vex: 20 > OK (Fig. 9.19)
Fig. 9.18
Position > On: binder
Fig. 9.19
The initial blank
151
On this page the process is defined (movement of tools): Process
Process step > Name: gravity > Downwards Gravity

Tool control > punch and binder: Stationary
Process step > Name: closing > Type: Binder wrap > Closing
Show all (small button on the right next to Tool control)
Tool control > die > Displcmnt > Velocity: 1
punch and binder: Stationary
cam: Non-active
Process step > Name: drawing > Type: Drawing Drawing

Show all > Tool control > die > Displcmnt > Velocity: 1
punch > Stationary > Relative tool: die > binder > Force > Constant
pressure > Value: 3 > Set > cam > Non-active >
In the fourth process step, the CAM tool forms the depression. CAM tool
Since, by default, three process steps are defined, a new one has to
be added:
Add process step … > (lower left)
The dialog Add process step is opened (Fig. 9.20)
Fig. 9.20
Dialog: Add process step ...
After making all entries as in Fig. 9.20, select:
152
Add process step … > (lower left)
Process step > Name: cam > Type: Flanging

Show all > Tool control > die > Force >Relative tool: punch > Con-
stant pressure > Value: 3 > Set >
punch: Stationary > binder: Stationary >
cam > Displcmnt > Velocity: 1
Attention:
Attention This process step is of the type Flanging.
Flanging This is necessary
as the working direction is not parallel to the z–axis.
Control – Input of numerical values

WriteRestart > off

Rslts > Curvature
Start of Simulation
Job > Start simulation ... > Kinematic check only > Start
The movement of the tools can be checked with the kinematic

check. If everything is defined correctly, the simulation can be
started without a kinematic check. (Kinematic check only – off).
153
Lesson 10: Use of Pad and Springback
2. 10 Lesson 10: Use of Pad and Springback
In this lesson a process using a pad is described. At the end of the lesson, springback is
calculated. Here, a pad means using an additional tool, which closes early with the
punch and which is then displaced by the punch to avoid wrinkles.
The geometry of the pad must be defined in these cases and new
tool displacements must also be defined on the Process page.
An U–shaped profile (Fig. 10.1) is used for this example. The geom-
etry exists in IGES–format.
Fig. 10.1
Example for use of a pad
afmesh_3.1 > OK
Check geometry for gaps

Generate part boundary: Apply Prepare
154
Check geometry for sharp edges

Fillet Check radius: 2.00 > Check
The message that (no) sharp edges have been found appears in log–
window. Close with the Dismiss button.
Check the geometry for undercuts

Tip Use the Tip page to check the geometry for undercuts. The check is
performed automatically; the results are shown in the main display.
The geometry is free of undercuts.
Fig. 10.2
Result of check for undercuts
Generate tools die, binder and punch

Prepare > Select faces of binder (right mouse button)
Now the selected patches are defined as the binder, unselected

patches are defined as the punch and all the patches are defined as
the die.
155
Fig. 10.3
Binder patches are selected

Model > Input generator ... > Simulation type: Incremental
The title is predefined but it can be changed.
The three tools die, punch and binder have already been defined on Tools
Tools page.
Switch on display of all tools:
Display > Tools ... > Show all > Dismiss
156
Fig. 10.4
Automatically defined tools by AutoForm
Punch and binder can be used for the simulation. For the die, the
upper patch must be deleted and defined as a separate tool, i.e., the
pad.
Switch to subpage named die on the Tools page, switch off display
of tools and switch on display of meshed geometry. Now we can
define geometry for the die:
Pick faces > Select the desired face with the right mouse button
(Fig. 10.5) > Deactivate > OK
157
Fig. 10.5
Selected patch will be the pad geometry and it must be deleted

from the die.
Define geometry for the pad. Add a new tool on the Tools page.
Add tool ... > Use settings of tool: die > Add tool
Because the die was used as reference tool for the pad, only name
and position have to be changed (Fig. 10.6).
Tool name > Name: pad (Fig. 10.6)

Pick faces > Select the desired face with the right mouse button
(Fig. 10.5) > Deactivate > Toggle active > OK
158
Fig. 10.6
Menu with input for the pad
Now four tools have been defined, die, punch, binder and pad. The
pad must be positioned by taking into account the position of the
die, so that punch first closes with the pad and the sheet is clamped
between these tools during the drawing process. Position of the pad
can be changed using Move–option on the Tools page (Fig. 10.6).
Move: 110 (positive direction, because the displacement should be

in the tool working direction).
Fig. 10.7 shows all tools in initial position.
159
Fig. 10.7
Defined tools in initial position
Columns for the binder have to be defined. In this example we use:
Columns > Blank center
The blank outline is defined in AutoForm as follows: Blank
Outline > Input ...> Curve Editor > Create points with right mouse
button > OK (Fig. 10.8)
Corner points of the blank can be defined with the right mouse but-
ton. Using the Shift key creates horizontal or vertical lines. Using
the Ctrl key creates arbitrary straight lines. The last point should be
the same as the first point. The following points specify the blank
outline:
P1: -220, 730, 0

P2: 560, 730, 0
P3: 470, 265, 0
P4: 470, 20, 0
P5: -170, 20, 0
Input exact coordinates in the curve editor after generation of points

with the right mouse button.
160
Outline > Edit ... > Curve Editor > Base > Select point with right
mouse button > input in input fields X and Y > OK
Fig. 10.8
Defined blank boundary
Process Process steps and tool movements are defined on the Process page:
Gravity gravity > Gravity: Upwards > die: Stationary > pad: Stationary
It is recommended to define pad during gravity as being Station-
ary. If the pad is specified as being Non-active, this tool would not
be checked for contact during the gravity process. This means that
an intersection of pad and sheet could occur.
In a following process step, the pad would be activated and the

intersection would cause a stop of the simulation run. To avoid this
problem it is therefore recommended to set pad Stationary (Fig.
10.9).
161
Fig. 10.9
Process step gravity
It is recommended to set pad Stationary during closing because of Binder wrap

reasons mentioned above (Fig. 10.10).
Closing > Tools > Show all > pad: Stationary
162
Fig. 10.10
Process step closing
Deep drawing During forming, the punch moves until it makes contact with the
pad. The pad is then set as force–controlled and it will be moved by
the punch until the punch closes with the die and the sheet is fully
formed. For this procedure several process steps are required:
• Punch moves until it makes contact with the pad,

• punch moves until closing with the die and the pad is com-
pleted (force controlled).
This means that the process step drawing must be interrupted, as

soon as the punch is in contact with the pad. The distance between
these tools is 390 mm (see Tools page Move value). Therefore, the
punch must move for 390 s (tool velocity is 1 mm/s – see Tool con-
trol v=1).
163
Name: drawing > Tool control > Show all > die: Stationary > Process
punch > Displcmnt > Velocity: 1 > Set
binder > Force > Relative tool: die > Const pressure > Value: 2 > Set
pad Stationary

Fig. 10.11
Process step drawing
After the above step is completed, deep drawing must be finished in

an additional process step:
Add process step ... > Forming > Use settings of forming step:
drawing > Insert position > Insert after > drawing > Add process
step
A new subpage appears which has to be completed (Fig. 10.12). In

this process step, the punch continues to move until it reaches the
bottom down position and displaces pad.
164
Fig. 10.12
Process step drawing2
Process Process step > Name: drawing2 > Type: Drawing >
die: Stationary > punch > Displcmnt > Velocity: 1 > Set >
binder > Force > Relative tool: die > Const pressure > Value: 2 >
Set > pad > Force > Relative tool: punch > Const pressure >
Value: 2 > Set (Fig. 10.13) >
165
Fig. 10.13
Pad is force–controlled; punch is the counter tool.
Attention:
Attention The pad is also now force–controlled. For this tool no col-
umn has been defined yet. If this is required, it must be done on the
Tools page (e.g. Columns > Tool center).
center
Springback
A new process step must be added to simulate springback.
Add process step ... > Springback > Add process step
The input page for the springback is very simple, no additional
input is required.
Control page
The inputs on Control page should be checked in Binding effects:
ThickSheet/Springback in later restart > ON

Layers > 7
WriteRestart > Off (Fig. 10.14).
166
Fig. 10.14
Setups on Control page
Start simulation run:
Analysis of Springback
After simulation run is completed successfully, reopen the simula-
tion file:
File > Reopen ...

To analyze springback results, we need to go to the end of the simu-
lation stage.
Time > Springback ...

Switch on the springback result menu:
167
Results > Springback …

Following menu appears:
Fig. 10.15
Springback menu
The part has to be fixed to avoid any rigid body motion. Therefore 6
boundary conditions must be specified. The first three fix the part in
z–direction, the next two fix the part in y–direction and the last fixes
the part in x–direction.
A part in space has 6 degrees of freedom (three rotational degrees of

freedom and three translations); to fix the part, we need to use the
Springback menu (Fig. 10.15).
The first three points fix the first three degrees of freedom (rotation
around x–axis, rotation around y–axis and translation in z–direc-
tion). The next two points fix the translation in y–direction and rota-
tion around the z–axis. The last point fixes the translation in x–
direction.
The first three points should be positioned so that they define a

plane, which has very little springback and which has only a small
angle to the xy–plane.
We choose the middle area and position the first three points.
Set Z1 > Define point with right mouse button
A menu appears (Fig. 10.16), saying that for definition of points the
increment before has to be used.
168
OK
Repeat for Z2 and Z3. The position is shown in Fig. 10.17.
Fig. 10.16
One increment back
Fig. 10.17
Z1,
Z1 Z2,
Z2 Z3 are defined
Points Y1 and Y2 should be positioned on a plane that has only a

small angle to the xz–plane (Fig. 10.18).
169
Fig. 10.18
Y1,
Y1 Y2 are defined
Point X1 should be positioned on a plane that has only a small angle

to xz–plane (Fig. 10.19).
Fig. 10.19
X1 is defined
After the 6 points have been defined (Fig. 10.20), press the button
Adjust to start the calculation of a rigid body motion which mini-
mizes the distances between the part and the defined points. Dis-
tances are shown in right area of the menu (Fig. 10.21).
170
Fig. 10.20
6 points from z–direction
Fig. 10.21
Distances which remain after pressing Adjust
Values shown in red are greater than sheet thickness.
To display the springback results in the main display, switch on

Normal displacement (Icon first row, right side). Adjust the scale to
minimum/maximum values of simulation using following options:
Results > Result variables … > Normal displacement
Results > Ranges … > Min/Max Simulation > Dismiss

171
The main display should be as shown in Fig. 10.22.
Fig. 10.22
Springback results – Normal displacement

172
Lesson 11: Hydromechanical Deep Drawing
2. 11 Lesson 11: Hydromechanical Deep Drawing
In this lesson an example is described using a fluid for the forming operation. Only
sheet metal forming processes can be simulated. Use the AutoForm–Hydro for tube
hydro forming.
Fig. 11.1
Tools for active hydro–mechanical deep–drawing
It should be noted that the procedure to describe a hydro–mechani-

cal forming process is the same as for a normal deep drawing pro-
cess. The two differ in the process schedule which is taken into
account on the Process page.
Tool setup is similar to the double action processes, which means

the die is below and the punch and the binder are located above.
The die only consists of a flat binder ring and a die radius. Often,
the binder also has a radius to allow pre–forming of the sheet into
the binder opening due to the increase in pressure of the fluid
below the sheet (Fig. 11.1).
173
Fig. 11.2
afmesh_3.1 > OK
Fig. 11.3
Faces of the binder surface are selected
Prepare > Select faces of binder (right mouse button)
Now the selected patches have been defined as the binder, unse-
lected patches are defined as the punch and all patches are defined
as the die.
174
Check geometry for gaps

Prepare Generate part boundary: Apply
Check geometry for sharp edges
Fillet Check radius: 2.00 > Check
The message that (no) sharp edges have been found appears in log–
window. Close with the Dismiss button.
Check the geometry for undercuts
Tip Use the Tip page to check the geometry for undercuts. The check is
performed automatically; the results are shown in the main display.
The geometry is free of undercuts.

Model > Input generator ... > Simulation type: Incremental >
Geometry refers to: punch side > OK
The title is predefined but it can be changed.
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)
175
Fig. 11.4
Menu: Reference tool geometry with activated option Pick faces
Select faces of the punch, binder radius and punch radius (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.
176
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 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
Dialog: 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).
177
Fig. 11.8
Dialog: Select curve with selected curves Curve 1,

1 Curve 2 and
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
178
Select vertical part of the blank boundary and confirm with OK

(Fig. 11.9 and Fig. 11.10).
Fig. 11.9
Blank page of Input generator
179
Fig. 11.10
Blank boundary with two symmetry lines
A double action process is already defined on the Process page. Process

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.
180
Fig. 11.11
Process page of Input generator
Input for Gravity (Fig. 11.12):
Process > gravity > Gravity: downwards > die: Stationary
181
Fig. 11.12
Process page of Input generator – subpage gravity
182
Process step binderwrap (closing) is already defined (Fig. 11.13).
Fig. 11.13
Process page of Input generator – subpage closing
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
183
On the right side of this option a selection of different fluid–based

forming options appears (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. Fig. 11.14
• 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).
184
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 pressure 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.
185
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
Menu: Active 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)
186
Fig. 11.17
Process page of Input generator – page drawing
Definition of all necessary input option is completed.

Job > Start simulation ...

187
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AutoForm–Incremental is the AutoForm module to simulate sheet

In AutoForm–Incremental the simulation of the following forming

• Impact of gravity when putting the blank sheet on the tool

Forming operations for steel and aluminum materials used in the

In connection with AutoForm–Optimizer, the user gets access to a

Lesson 1 Deep–Drawing on Double Action Press . . . . . . . . . . . . . . . . . 5

Lesson 2 Deep–Drawing on Single Action Press.

Lesson 3 Drawbeads and Tailored Blanks . . . . . . . . . . . . . . . . . . . . . . . 47

Lesson 4 Drawbead generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

• Automatic determination of the width

Lesson 5 Tipping and Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

• Determination of the drawing direction

Automatic Filleting with a Constant Radius . . . . . . . . . . . . . . 110 Lesson 7

• Starting from Restart–File

Using CAM Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Lesson 9

Use of Pad and Springback.

• Die insert (pad)

Hydromechanical Deep Drawing . . . . . . . . . . . . . . . . . . . . . 173 Lesson 11

2. 1 Lesson 1: Deep–Drawing on Double Action Press

Deep drawing on a double action press

Generation of a Simulation file

The generation of the simulation file is done by the following input:

File > New ... > in_lesson_01 > OK

Options to create a new simulation file

• File name: name of *.sim file, without extension

Preparation of tool geometries for the simulation

The tool geometries are read in VDAFS– or IGES format. AutoForm

Import and meshing of CAD data

Select a file: in_lesson_01.igs > OK

Window to mesh CAD data

Start meshing with the option:

Program: afmesh_3.1 > OK

• Error tolerance: Acceptable chordal error for the meshing. Parameters

• Treat only: Only specified faces will be meshed. Faces

• Treat only: Only specified layers will be meshed. Layers

The meshed geometry is immediately displayed and the Geometry

In this example the CAD data is binder (binder) and punch

Select faces of binder (right mouse button or Shift – right mouse

Selected faces of binder

Define objects: Binder Prepare

Binder is defined in Geometry generator and selected faces are put

Control parameters can be found in Part boundary (Fig. 1.5):

• Error tolerance is the acceptable chordal error of the CAD

Generate part boundary: Apply (Fig. 1.5 bottom right)

to start automatic calculation of the part boundary (shown in blue).

Generated part boundary

Prepare Outer Trim > Edit

Holes can be created with the option

Inner Trim > Add…

Correction of untrimmed surfaces should be performed in CAD

Check geometry for sharp edges:

In the log–window, it is displayed that (no) sharp edges have been

Close the window using Dismiss (Fig. 1.8).

Fillet page of Geometry generator

Check geometry for undercuts using option:

Geometry generator > Tip (Fig. 1.9)

Tip page of Geometry generator

Tip Display > Backdrafts in the Geometry generator.

Generate simulation input

Model > Input generator ... > Simulation type: Incremental

Dialog: Simulation Type to create simulation input

• Simulation type: Incremental simulation, OneStep simula-