Forming Technologies Inc

Contents

▪ Introduction to CATSTAMP

▪ Demonstration

▪ Installation & Licensing

▪ Support

9/16/2021 © 2008 FTI Confidential

 ▪ Associative and regenerative
formability analysis tool
▪ Quickly identifies splitting, wrinkling and
thinning
▪ Evaluate alternate part designs and
processing conditions such as pressure
pads, draw beads, and binder layout
▪ Accurately predicts feasibility of binder
and addendum geometry
▪ Substantially reduces process
development time by accurately sizing
blanks
▪ Fully integrated into CATIA V5 native
environment
▪ Complete analyses in minutes

9/16/2021 © 2008 FTI Confidential

 CATFORM vs CATSTAMP

CATSTAMP includes all the functionality that is available in CATFORM plus

▪Curved Binder: Analyzes the forming process that starts with a curved binder that creates a curved
blank. The curved blank will typically result in more material being available for the forming operation

▪Draw Beads: This forming condition can be used to simulate the control of material flow into the die
cavity using a draw bead or a lock bead.

▪Safety Margin Plot: Displays the relative strain between the FLC and major strain value at each
node.

▪Forming Displacement Plots (Magnitude, X, Y & Z): Displays the various displacement
components as calculated between the part and blank.

▪Equivalent Stress Plots: The hypothetical stress required to deform the material by the equivalent
Strain amount in a uniaxial tension test.

▪Equivalent Strain Plot: The hypothetical strain representing the sum of the Thickness, Major and
Minor strains values in a uniaxial tension test.

▪Punch Force Calculation: Displays the force required to deform the material.

▪Point Mapping: Allows points to be mapped from the part to the blank shape

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 Demonstration

CATSTAMP Analysis
▪ Setting up the Geometry
▪ Solving
▪ Analyzing the Results
Part Geometry

Binder Geometry

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 Define Geometry

▪ Open the file CATSTAMP.CATPart

CATSTAMP requires a knitted surface model

representing the top, bottom, or mid-surface of the
part. If you are working with a solid model, a surface
model can be extracted using CATIA functionality
such as the Extract and Offset commands.

▪ Select the External View command from the

Tools menu

▪ Select the feature called Healing.1 and

select OK

9/16/2021 © 2008 FTI Confidential

 Apply a Material

▪ Select the Apply Material button on the Apply Material toolbar.

▪ Select the Steel from the Library window and drag and drop it onto the part.

▪ Select the OK button in the Library window to apply the material

9/16/2021 © 2008 FTI Confidential

 Open a New Forming Analysis

▪ Open a new Forming Analysis by selecting FTI Forming Analysis workbench from the
Start > Analysis & Simulation pulldown.

▪ Specify a CATSTAMP Case in the New Analysis window and

select OK

9/16/2021 © 2008 FTI Confidential

 Material Selection

The standard CATIA material library does not support the material properties required to run a forming
analysis, these important properties must be defined in the FTI Forming Analysis workbench. This also
enables us to model different materials in different areas of the part to represent a tailor welded blank.

▪To define a material, select the Material Selection icon from the
Forming toolbar.

▪Select the material CRDQ from the list

▪Select the OK button to accept the material type

9/16/2021 © 2008 FTI Confidential

 Material Selection

▪To define the material thickness, double click on the thickness label on the graphic screen and
key in a material thickness of 2 mm in the Shell Property window.

9/16/2021 © 2008 FTI Confidential

 Tipping

Most CATIA models are constructed in the assembly position. This is usually not the position the part
will be formed in. For this reason, we must define the press direction prior to running the analysis.

▪ To set the press direction (or “tipping” position), select the Tipping & Symmetry button on
the Forming toolbar.

▪ In the Tipping & Symmetry window check the Auto Tipping option to automatically calculate
tip position for the part.

▪ Select the OK button.

9/16/2021 © 2008 FTI Confidential

 Meshing
The Mesh Parameters are automatically defined by CATSTAMP. This step is only required if the user
does not want to use the recommended default mesh size.
▪To view the mesh parameters double click on the Part Mesh in the Specifications
tree as shown below.

The OCTREE Triangular Mesh window will appear with a recommended mesh size and absolute
sag value defined. The size value should typically lie in the range of 10 – 40 mm. The Absolute Sag
should typically be set between 0.1 – 0.5 mm.

9/16/2021 © 2008 FTI Confidential

 Curved Binder

The CATSTAMP analysis is performed with a default flat binder. In many cases, the actual forming
starts with a curved binder that creates a curved blank. The curved blank usually results in more
material being available for the forming operation. This extra material has a significant effect on the
results depending on the forming conditions that were applied.

To run a curved binder analysis you must have a surface representing the binder geometry. The
binder shape must be developable and must be large enough to contain the developed blank shape
for the model. A separate mesh must be created for the curved binder geometry.
▪Select the Octree Triangular Mesher icon from the forming toolbar and select the curved binder
geometry called Binder

Binder geometry

▪Select the OK button in the OCTREE Triangular Mesh window to accept the default mesh settings

9/16/2021 © 2008 FTI Confidential

 Solving

When the model set up is complete, the final step before viewing the results is meshing and solving. In
CATSTAMP V5, this is combined into one step.
▪Select the Mesh & Compute icon from the Forming toolbar.

▪To start the analysis, set the drop-down box to All and press OK. This will first
mesh the part and then run the solver.

Once you have generated results, any changes to the input geometry or analysis setup will cause the
solver and possibly the mesher to re-run when you try to reactivate a result plot. This update
mechanism ensures that the analysis results are always consistent with the current model.

9/16/2021 © 2008 FTI Confidential

 Results

▪Hold down the CTRL key and select each of

the branches in the Specifications tree as
shown.

▪Right click and select the Hide/Show option to

hide each branch.

9/16/2021 © 2008 FTI Confidential

 Results: Safety Zone
The Safety Zone plot is a simple and quick qualitative result that can be used to evaluate the
manufacturability of a part. The safety zones can be used to identity areas of splitting and wrinkling.
Each color represents a different zone. The zones are listed in the plot legend.

▪To view the Safety Zone plot, drag and drop the Safety Zone icon from the Forming toolbar to the
CATSTAMP Forming Solution Set folder

9/16/2021 © 2008 FTI Confidential

 Results: Safety Zone

To hide the binder geometry in a plot, edit the definition of the plot and turn on the part geometry filter.

▪Right click on the Safety Zone plot in the Specifications tree and select Safety zone object ->
Definition

▪On the Selections tab click on Part Mesh and select OK.

Failure

Wrinkles

9/16/2021 © 2008 FTI Confidential

 Multiple Forming Cases

Multiple Forming Scenarios can be analyzed at once to compare the effects of different settings on the
analysis results. Unique tipping positions and forming constraints can be applied to each forming case.

▪To add a second forming case select

Stamping Case from the Insert menu.

Each forming case will be listed as a unique branch in

the Specifications tree. The active forming case will be
underlined. To view the results from the non-active CASE #1
forming case, right click on the forming case and select
Set As Current Case

CASE #2
(active)

9/16/2021 © 2008 FTI Confidential

 Tipping

Each Forming Case can have a unique tipping direction. We will use the Auto Tipping command to
define the tipping direction for the new Forming Case.

▪ To set the press direction (or “tipping” position), select the Tipping & Symmetry button on
the Forming toolbar.

▪ In the Tipping & Symmetry window check the Auto Tipping option to automatically calculate
tip position for the part.

▪ Select the OK button.

9/16/2021 © 2008 FTI Confidential

 Process Conditions: Blankholder Force

To more accurately simulate the sheet metal forming process, CATSTAMP is capable of simulating
process conditions such as friction, uniform or variable blankholder forces, pressure pads, draw beads
or clamps.

A uniform blankholder force applies a uniform

edge tension to the boundary of the part during
simulation. This will lead to additional stretch in
the model and will help reduce wrinkling.

▪To apply a blankholder force to the part, select the

Friction and Blankholder icon on the Forming
toolbar.

▪Define a Medium blankholder force and select OK

to apply the condition.

Additionally, you can modify the friction

coefficient used during the analysis to simulate
special lubricants or coatings.

9/16/2021 © 2008 FTI Confidential

 Process Conditions: Draw Bead

A draw bead is a ridge constructed around a portion of a die cavity to control material flow. A groove in the
mating blank holder allows the die to close. A draw bead is defined in CATSTAMP by a specifying its
location and force.

▪To apply a draw bead to the part, select the Draw

Bead icon on the Forming toolbar.

▪Show the folder called Drawbead Geometry located

under the Links Manager.1 branch

▪Select the polyline on the model as shown and key

in a draw bead force of 500,000 N/m2.

▪Select OK.

9/16/2021 © 2008 FTI Confidential

 Solving

When the model set up is complete, the final step before viewing the results is meshing and solving. In
CATSTAMP V5, this is combined into one step.
▪Select the Mesh & Compute icon from the Forming toolbar.

▪To start the analysis, set the drop-down box to All and press OK. This will first
mesh the part and then run the solver.

Once you have generated results, any changes to the input geometry or analysis setup will cause the
solver and possibly the mesher to re-run when you try to reactivate a result plot. This update
mechanism ensures that the analysis results are always consistent with the current model.

9/16/2021 © 2008 FTI Confidential

 Results: Safety Zone

▪To view the Safety Zone plot, drag and drop the Safety Zone icon from the Forming toolbar to the
CATSTAMP Forming Solution Set folder

Failure Zone

Note: For this example, all

points of failure occur because
the thinning rate of 23% is
exceeded. See thinning plot
later in this exercise.

Wrinkles reduced
but still present

9/16/2021 © 2008 FTI Confidential

 Results: Thickness Strain
The Thickness Strain plot displays the percentage change in material thickness after the forming
process. The percentage change in material thickness can be used to check for excessive thinning
(negative values) or thickening (positive values). Note: typical thinning limit for steel is -23%.
▪To view the Thickness Strain plot, drag and drop the Thickness Strain icon from the Forming
toolbar to the CATSTAMP Forming Solution Set folder

➢ To inverse the color display on

the plot, double click on the
legend and check the option
inverse in the Color Map
Edition dialog

➢ Move the mouse cursor over an

area of the plot to view the
thinning rate in that area.

Minimum thinning rate

of -30%

9/16/2021 © 2008 FTI Confidential

 Results: Forming Limit Diagram

The strain distribution for all the nodes on the part can be
displayed on the Forming Limit Diagram (FLD). The FLD
can be used to determine the forming mode and the
formability of the part in a local area.

▪To view the Forming Limit Diagram, select the

Forming Limit Diagram icon on the Forming
toolbar
Thinning Rate is
set to 23%

* The FLD is an interactive diagram if the Safety

Zone plot is activated and a point or group of
points are selected on the FLD their location will
highlight on the Safety Zone plot

9/16/2021 © 2008 FTI Confidential

 Results: Blank Shape

CATFORM develops the optimal blank shapes for the part accounting for material stretch and deformation.

▪Select the Deformed Blank icon and drag and drop it to the CATFORM Forming Solution Set
folder in the Specifications tree.

Note: Select the Shading with Edges render style to

display mesh elements on the Blank Shape

9/16/2021 © 2008 FTI Confidential

 Results: Blank Shape
▪An associative surface can be created from the blank shape by selecting the Create
Blank Face Feature icon on the Forming toolbar.

▪A non-associative surface can be created from the blank shape by selecting the
Create Blank Face icon on the Forming toolbar.

▪A surface can also be created of the blank shape on the curved binder by selecting
the Create Blank Face on binder icon on the Forming toolbar.

Blank Face on
Binder

Part

9/16/2021 © 2008 FTI Confidential

 CATSTAMP Licensing

➢ To obtain a license, you must send Forming Technologies (FTI) your

computers Forming ID number.

➢ To get your Forming ID number double click on the lmformingid.txt file

which can be found in your CATSTAMPV5 directory.

➢ Send an email with your name, company name and Forming ID number to
support@forming.com and a license file will be emailed back to you.

➢ When you receive your license, place it in the C:\FTI\FTICATIAV5Rxx

folder

9/16/2021 © 2008 FTI Confidential

 Questions & Answers

▪ Sales & Marketing

sales@forming.com
905-340-2997

▪ Support
support@forming.com
905-340-2997

9/16/2021 © 2008 FTI Confidential