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3 AutoForm–DieDesigner

AutoForm–DieDesigner has been developed to generate tool con-

cepts in an early stage of tool design and to evaluate these concepts
by deep drawing simulation. The functions of AutoForm–DieDe-
signer reflect these requirements:

• Automatic variable filleting of sharp geometry edges

• Powerful functions for determining the drawing direction
• Rapid solution for finding ideal part position of double
attached parts
• Automatic and interactive filling of holes, boundary fill or
generation of fill faces between double attached parts
• Modification of tool and part geometries
• Automatic or interactive generation or modification of a
binder surface
• Automatic or interactive generation of outer or inner
addenda
• Full parameterization

Main focus has been placed on providing an easy–to–use interface.

Furthermore, development and modification of tool surfaces can be
done very quickly. As for other AutoForm modules many processes
run in the background automatically without user intervention. For
complex parts the user can modify the automatic solution at any
time. Especially key profiles can be chosen arbitrarily.

AutoForm–DieDesigner is fully parametric: All user settings and

input are stored in the simulation file for easy modification. Simi-
larly, the parametric data structure allows for automatic redesign. If
the user changes the binder for example, all profiles are adapted to
the new geometry by pressing one button only. Even a full change
of part geometry is permitted, the entire addendum will change
automatically. Another target is automatic optimization of adden-
dum. AutoForm–Optimizer is fully integrated in AutoForm–Incre-
mental, AutoForm–OneStep and the user interface.

AutoForm–DieDesigner has not been developed to design a full

serial tool. The necessary surface quality should be ensured by
using a CAD–system. The required CAD–interfaces (IGES, VDAFS)
are implemented in this version to a large extent.

1
The current version 3.1 is the second DieDesigner–release. Despite
intensive research and development there are still a number of func-
tions which require further improvement. In detail these are:

• Automatically laid–out flanges

• Full implementation of symmetric parts
• More complex Addendum profiles

All these items are user requests and are currently under develop-
ment. Our team appreciates suggestions and will do its best to solve
those problems.

This manual is designed to give the user practical advice in hand-

ling AutoForm and achieving good calculation results. A number of
examples explain the design of typical tools step by step. In addi-
tion to the overall features they will introduce the Curve editor for
designing and modifying lines globally and locally. Lesson six of
the AutoForm–Incremental workshop deals with automatic optimi-
zation of tools generated with AutoForm–DieDesigner. The user
will be able to define an optimization and learn about the available
geometry parameters.

2
Contents of the Workshop „AutoForm–DieDesigner“

Lesson 1 Basic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

• Reading in the part geometry

• Basics on the addendum
• Profiles
• Master–Profile
• Individual profile
• Punch opening line
• Bar height line
• Exporting tool surfaces

Lesson 2 A simple Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

• Definition of the symmetry–plane

• Closing all holes (All holes)
• Boundary fill (Bndry fill)
• Generating a binder using Auto–Binder
• Generating a simple addendum

Lesson 3 Profile Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

• Registers on the Prepare page

• Manual modification of the profile orientation
• Generating a binder using Auto–Binder
• Modifying the punch opening line
• Modifying the master–profile
• Generating individual profiles
• Generating a bar on the addendum

Lesson 4 From DieDesigner to Deep Drawing Simulation . . . . . . . . . . . 36

• Boundary fill
• Generating a binder using Auto–Binder
• Changing the profile orientation
• Importing a binder surface
• Importing a punch opening line
• Smoothen the die radius
• Preparing and starting the deep drawing simulation

3
Creating a Binder Surface with Lesson 5
Auto–Binder and Manual–Binder . . . . . . . . . . . . . . . . . . . . . . 46

• Generating a binder using Auto–Binder

• Generating a binder surface using Manual–Binder
• Generating and modifying binder–profiles
• Exporting of the binder surface and binder–profiles

Defining the Drawing Direction (Tip)

(Tip).. . . . . . . . . . . . . . . . . . . . 55 Lesson 6

• Displaying backdrafts and drawing angles

• Defining the tipping center
• Automatic functions for the determination of the drawing
direction
• Manual determination of the drawing direction
• Analyzing the drawing direction

Modification of Product and Tool Geometries . . . . . . . . . . . 61 Lesson 7

• Outer trim
• Inner trim
• Global and variable filleting of sharp edges
• Overcrowning part and tool geometries
• Add detail
• Exporting fill faces

A Tool with Inner Binder and Inner Addendum . . . . . . . . . . . 77 Lesson 8

• Importing a binder surface

• Generating an inner addendum
• Generating an outer addendum

Development of a Tool for Double–attached Part . . . . . . . . 82 Lesson 9

• Mirroring left and right parts

• Defining a symmetry–plane for left and right parts
• Generating and modifying fill areas between double
attached parts
• Generating a binder surface using Manual–Binder

Appendix 1: Useful Tips and Techniques . . . . . . . . . . . . . . . . 92

Appendix 2: The Tip Page . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Appendix 3: The Addendum Page . . . . . . . . . . . . . . . . . . . . 102

4
 Lesson 1: Basic Functions

3. 1 Lesson 1: Basic Functions

Using a simple part geometry, we describe the basic procedure for the generation of
an addendum in AutoForm–DieDesigner. The part geometry is imported and a binder
is generated automatically. We show that the parametrically generated faces will be
adapted automatically, if the binder is modified. Finally, we describe the export of sur-
faces and curves.

Creating a new Simulation

User interface File > New

The New file dialog opens:

Fig. 1.1

Dialog: New file

Use the default settings for units and tolerance. Enter the following
file name:

File name: lesson1 > OK

The Geometry generator opens.

Reading the Part geometry

Select from the menu bar of the Geometry generator:

File > Import ... > af > OK > Files: dd_lesson_01.af > OK

The geometry is automatically assigned to the Part register. Simul-

taneously, the geometry is shown in the main display and the Pre-
pare page of the Geometry generator is opened. Use the Display
part function to switch on/off the display of the Part register.

5
Lesson 1: Basic Functions

Note: A detailed description of the registers will be given in Lesson

3.

Generating the Part Boundary

To use the functions of the Geometry generator, the part boundary
must be available. Generate the part boundary by clicking

Apply Prepare

The part boundary is represented by a blue line.

Fig. 1.2

Part with Part boundary

Generating a binder surface using Auto–Binder

Go to the Binder page to generate the binder surface.

Auto > Apply Binder

Fig. 1.3

Part and binder surface

6
 Lesson 1: Basic Functions

Generating an outer Addendum

In principle, you can generate inner and outer addenda with DieDe-
signer. For this example, an outer addendum is needed.

Addendum Add addendum ... > Pick curve: Curve1 > OK

The Addendum page is shown in Fig. 1.4:

Fig. 1.4

The Addendum page

The functions of the Addendum page will be described in Appen-

dix 3.

7
Lesson 1: Basic Functions

An ordinary drawing tool consists of the part geometry, the binder

surface and an addendum. In forming processes, the addendum in
general performs the task to make a suitable transition from the part
to the binder.

In AutoForm, the addendum is created on the basis of several pro-

files.

Fig. 1.5

Addendum created on the basis of several profiles

The master–profile as shown on the Addendum page is the refer-

ence profile for the individual profiles. The essential parameters of
the addendum (bars, radii and angles) are determined by the mas-
ter–profile. The heights and lengths vary for different distances
between the part and the binder.

In addition, it is possible to create any form of addendum by means

of modifying individual profile parameters.

Modifying the Master–profile

Modifying the Punch–Opening–Width
Modify the punch–opening–width on the Addendum page:

PO: 50 or alternatively Addendum

Click the vertical line and move it to about 50 mm > Apply

8
 Lesson 1: Basic Functions

The tool is shown in the main display.

Enlarging the Binder surface

Go back to the Binder page:

Binder Adv > Min flange width: 200 > Apply

The binder surface has been enlarged, but the Addendum page is
shown in red. This is, because the addendum has not yet been con-
nected to the binder surface. Go to the Addendum page:

Addendum Apply

The tool with the new binder surface is generated.

Changing the Die radius

We will change the die radius in the lower left corner (from +z
view). Switch on the display of all profiles. Go to the Addendum
page:

Addendum Options > Show all

Generating additional individual Profiles

To change the die radius it is necessary to define several individual
profiles and to modify them afterwards. The numbers of the indi-
vidual profiles may differ; the approximate position of the profiles
with respect to lower left corner of the part is important.

Definition of individual profiles:

Add prf … > Select > Profile: 64 > Add

Add prf … > Select > Profile: 68 > Add
Add prf … > Select > Profile: 75 > Add
Add prf … > Select > Profile: 79 > Add

Alternatively, select the profiles with the right mouse button:

Profile 64 > Add

Profile 68 > Add
Profile 75 > Add
Profile 79 > Add

9
Lesson 1: Basic Functions

The individual profiles should be as shown in Fig. 1.6:

Fig. 1.6

Individual profiles (marked red)

Note:
Note Defined profiles can be copied: Select the profile with the
right mouse button and while holding the mouse button down drag
the profiles. Release the mouse button at the desired position.

Modifying individual Profiles or Die radius

Select Profile 75 on the Addendum page:

Advanced ... > Die radius: 10 > Return > Dismiss Addendum

Select Profile 68:

Advanced ... > Die radius: 10 > Return > Dismiss

and finally click on Apply

The addendum should be as shown in Fig. 1.7:

10
 Lesson 1: Basic Functions

Fig. 1.7

Addendum after modifying the individual profiles

Note:
Note Modifications on individual profiles only affect the neighbor-
ing individual profiles.

The radii can be changed using the mouse: Select the arc line with
the left mouse button and while holding the mouse button down
drag the line. The respective radius is indicated above the profile
window.

Creating a Bar
As described above four individual profiles have to be determined
in order to create the bar modification: The outer profiles (delimit-
ers) to fix the original state and the inner two profiles to be modi-
fied. Modification will occur between the inner two profiles and
transition out to the original state at the outer profiles. In this case,
besides the existing Profile 79, three additional individual profiles
have to be defined.

Definition of additional individual profiles:

Addendum Add prf … > Select > Profile: 83 > Add

Add prf … > Select > Profile: 96 > Add
Add prf … > Select > Profile: 100 > Add

Alternatively, select the profiles with the right mouse button:

Profile 83 > Add

Profile 96 > Add
Profile 100 > Add

11
Lesson 1: Basic Functions

Activate Profile 96 (Tab on the Addendum page or select the profile

in the main display). Select the rightmost profile template (Bar).

Note:
Note All profile templates will be described in Appendix 3.

To modify the profile, click the horizontal line and move it to a

height of 10 mm or enter:

Heights: > Bar: 10

Do the same for Profile 83 and finally click on

Apply

Modifying the Bar

Activate Profile 96 and select the 5th profile template (Step). Do the
same for Profile 83 and finally click on

Apply

Fig. 1.8

Addendum after modifying the bar

Modifying the Punch Opening Line

The punch opening line, which has been created automatically, will
be modified now. Use the command:

Lines ... > PO width: > Edit ... Addendum

The Curve editor opens. Use the right mouse button to click on a
node and drag it. The punch opening line is now modified. Points

12
 Lesson 1: Basic Functions

can be added, deleted and moved in this way until the desired
punch opening line is displayed. Click

OK

to accept the line and then adapt the profiles to the new punch
opening line.

Fig. 1.9

Modified punch opening line

Alternatively, use the global modification mode of the Curve editor:

Addendum Lines ... > PO width: > Edit... > Global mod
Fig. 1.10

Global modification parameters for the punch opening line

• Move the Convex slider to the right so that the PO line

becomes convex.

13
Lesson 1: Basic Functions

• Move the Expand slider to the right to expand the line.

Slide it back to 0.
• Move the Smooth slider to the right to smoothen the line.
Slide it back to 0.

Finally click: OK

Editing the Bar Height line

The bar height line is the highest point of the bar.

Switch on the display of all profiles. Go to the Addendum page:

Options > Show profiles Addendum

Only the individual profiles are displayed. To edit the bar height
line use the command:

Lines ... > Bar height: > Edit ...

Fig. 1.11

Editing the bar height line

Rotate the tool to a position as shown in Fig. 1.11. Click on the line
between the two points, which determine the bar (right mouse but-
ton) and drag the point. The point can only be moved in the z–direc-
tion. Move the point in such a way that a convex profile is formed.
Finally click on

OK

The addendum is now adjusted to the bar height line.

14
 Lesson 1: Basic Functions

Editing the Counter Bar Height–Line

The Counter bar height line describes the position of the counter bar
with respect to the part boundary. Rotate the model in such a way
that you view the bar from the part. You see that the transition of
the profile between part and bar is no longer plane but that it is
ascending due to modification of the bar height line.

Adjust the individual profiles 83 and 96

Addendum Heights: > CB: Free

and afterwards modify the CB line:

Lines ... > CB height: > Edit ...

Delete all the nodes between Profile 79 and 100 to smoothen the line
again. To do so click the nodes in the main display with the right
mouse button; press the Del key to delete the nodes. Finally click on

OK

to get a plane addendum in this region.

The bar height line and the CB height line are used to smoothen
addendum regions and to get a uniform punch contact.

Changing the Drawing Depth

The default value for the drawing depth is 20 mm. This value is to
be changed. You can take advantage of the parameterized adden-
dum generation: All profiles are automatically adjusted to the new
drawing depth.

Go back to the Binder page:

Binder Shift: 40 > Enter

Go to the Addendum page and click on

Addendum Apply

15
Lesson 1: Basic Functions

Exporting Tool Surfaces

The tool surfaces generated in DieDesigner can be exported in IGES
or VDAFS format:

The faces of the addendum are exported as follows:

File > Export surfaces … > Addendum Geometry Gen-

erator
The binder surface is exported as follows:

File > Export surfaces … > Binder > Binder surface / Binder ring

Fig. 1.12

Exporting tool surfaces

16
 Lesson 1: Basic Functions

Exporting Profiles
Similarly, profiles can be exported in IGES, VDAFS or AF format:

Geometry Gen- File > Export addndm profiles … > Profiles > OK
erator

Fig. 1.13

Exporting profiles

Saving the Data

User interface File > Save

17
Lesson 2: A simple Tool

3. 2 Lesson 2: A simple Tool

This lesson describes the complete work flow for the generation of a tool basing on a
simple part geometry. Besides the addendum and binder generation as described in
Lesson 1, the functions for mirroring symmetrical parts, the filling of holes and boundary
fill are introduced in this lesson.

Fig. 2.1

Left part of the part geometry

Creating a new Simulation

File > New > File name: lesson2 > OK User interface

Importing the Part Geometry

Only one half of the part geometry is available in af format for this
lesson. The complete part is created by mirroring the available half
about a symmetry–plane.

File > Import > af > OK > Files: dd_lesson_02.af > OK Geometry gen-
erator

18
 Lesson 2: A simple Tool

Defining the Symmetry–plane and Generating the Part Boundary

Before mirroring the geometry, a symmetry–plane has to be
defined.

Prepare Symmetry/double …

Fig. 2.2

Definition of Geometry type and Symmetry plane

Use the second icon (Symmetry, half input) in the area Geometry
type to indicate that only one half of the symmetrical geometry has
been read. This half of the geometry will be mirrored about the
symmetry–plane.

Prepare Symmetry, half input > x-z-plane > y: 0 > OK

Generate the boundary by clicking on

Apply

Automatic Filling of all Holes

Select the Modify P page and accept the default settings.

Modify P All holes > Apply

Boundary Fill
Go to the Bndry page. Before generating an outer addendum, all
holes have to be filled and the part boundary has to be smoothened.
The generated outer fill faces are called boundary fill. The outer
boundary fill line is determined by tangential points created by a
roll cylinder moving around the part boundary and its roll radius.
The new boundary is called the zero line.

19
Lesson 2: A simple Tool

Add bndry fill … > Pick curve: Curve1 > OK Bndry

Bndry fill roll radius: 500

Finally click on Apply.

Fig. 2.3

Geometry after mirroring, filling holes and boundary fill

Generating a Binder Surface with Auto–Binder

Use the Auto–Binder function to quickly generate a binder surface.
Accept the default settings as in Lesson 1 with the exception of set-
tings of the drawing depth. Select Uniform to achieve a uniform
drawing depth over the whole part.

Auto … > Drawing depth: Uniform > Apply Binder

Fig. 2.4

Binder surface and representation of the drawing depth over the

part

20
 Lesson 2: A simple Tool

Generating an Outer Addendum

To generate an outer addendum go to the Addendum page. Select
the zero line:

Addendum Add addendum … > Pick curve: Curve1 > OK

A new tab called Outer is added to the Addendum page. Move the
mouse (without clicking) over the six template icons at the bottom
of the page to see available pre–defined profile templates. Use the
Smooth template for the master–profile. Accept the default settings
with the exception of Punch opening width:

PO: 50

or: Move the vertical line up to 50

Fig. 2.5

Master–profile with Smooth template

Note:
Note Fig 2.5 shows the current settings of the master–profile and
the original state before changing the PO width (dashed line).

Finally click on

Addendum Apply

The complete tool is as shown in Fig 2.6:

21
Lesson 2: A simple Tool

Fig. 2.6

Complete tool (PO

PO line active in Curve manager)

Saving the Data

File > Save User interface

22
 Lesson 3: Profile Orientation

3. 3 Lesson 3: Profile Orientation

Some parts contain „Feature lines“. These typical lines should continue in the adden-
dum of the tools with the same orientation to ensure a good material flow. This lesson
describes how to adjust or to change the profile orientation in DieDesigner.

Fig. 3.1

Tool for a decklid

Creating a new Simulation

User interface File > New > File name: lesson3 > OK

Importing the Part Geometry (Left Part)

Only the left half of the part geometry is available in af format for
this lesson.

Geometry Gen- File > Import > af > OK > Files: dd_lesson_03.af > OK
erator
Defining the Symmetry–plane
For the generation of a complete tool the left half of the part has to
be mirrored. Define the symmetry–plane.

Prepare Symmetry / double …

Symmetry, half input > x-z-plane > y: 0 > OK

23
Lesson 3: Profile Orientation

Fig. 3.2

Mirrored part geometry

Flange Faces and the Register Deleted

In this decklid the license plate bay will be formed in a secondary
operation, i.e. this region is not considered for the generation of the
drawing tool.

You can assign faces to the different registers on the Prepare page:

• Part: Contains the CAD faces for the part, which are
needed for the generation of the tool.
• Binder: Contains the faces of the part geometry, which are
placed directly on the binder surface. (The binder surface is
generated or imported on the Binder page later). This
should be used only if the complete tool surfaces have been
read in from CAD. Selected faces are then assigned to the
Binder register.
• Flange: Register for CAD faces needed for subsequent
operations.
• Deleted: Not used faces.

Select the faces of the license plate bay (Shift - right mouse but- Prepare
ton)

24
 Lesson 3: Profile Orientation

The selected faces are shown in yellow.

Fig. 3.3

Part with the selected faces of the license plate bay

Prepare Define objects: Deleted

Click the Deleted button to assign the selected faces to Deleted reg-
ister. The selected faces are no longer shown in the main display.
Use the button Display deleted to display the faces again.

Now we generate the part boundary.

Prepare Generate part boundary: Apply

Note:
Note The part boundary is generated only for the faces assigned
to the Part register.

No further information has to be entered on the Prepare page.

Closing Holes contained in the Part Geometry

Go to the Modify P page. The remaining hole will be closed:

Modify P Add hole > Pick curve > Select the hole in the main display (right
mouse button) or from the lists > OK

Apply

25
Lesson 3: Profile Orientation

Fig. 3.4

The hole closed by fill faces.

If necessary, you can modify the fill faces by means of control

curves. Using control curves will be described in Lesson 7.

Generating a Binder Surface with Auto–Binder

Go to the Binder page.

Auto Binder

Define the settings of the binder on the Auto–Binder pages (some of

the default settings can be accepted). Make the following changes
on the Binder page:

Drawing depth: Uniform > Surface profile: Max bndry slope: Binder
30.00 deg > Angle diff.: 30.00 deg > Flexibility: 0.70

Adv > Min flange width: 250 > Apply

The binder surface is generated automatically. For the modification

of the binder surface, the above setting can be changed. Click Apply
to generate the new binder surface.

Generating the Outer Addendum

Add addendum ... Addendum

Only an outer addendum is needed for this decklid. Select the outer
curve with the right mouse button (in the main display) from the
list.

Pick curve: > Curve 1 > OK

A new tab called Outer is added to the Addendum page.

26
 Lesson 3: Profile Orientation

Using a simple master–profile, the first version of the addendum is

generated. The distance between the part boundary and the punch
opening line is set to 140 mm.

Addendum Widths > PO: 140 > Apply

The first version of the tool consisting of binder surface, addendum

and part is shown in the main display.

Adjusting Profile Orientation manually

The addendum consists of a number of profiles between the part
boundary and the punch opening line. The automatically defined
profile orientation is approximately perpendicular with respect to
the part boundary.

For the decklid profile orientation has to be changed in certain

areas. Go to the Addendum page and click on

Addendum Directions

Note:
Note Adjust the view to positive z–direction to change the profile
orientation by means of Directions.
Directions

Fig. 3.5

Automatic profile orientation (green and red profiles) in the adden-

dum

27
Lesson 3: Profile Orientation

Procedure to change the Profile Orientation

• You see red and green profiles in the addendum. Clicking
the profile, the color changes from red to green and vice
versa.
• Changes can be made to the red profiles. Drag the profile
with the right mouse button held down.

Note:
Note After zooming in the relevant area, you get the best results by
clicking the right mouse button the red profiles as close as possible
to the punch opening line and by dragging them with the mouse
button held down

• Changing a red profile, the changes are automatically valid

for the neighboring profiles. The changes are valid for the
area limited by two red profiles.
• By clever determination of red and green profiles you can
locally arrange any profile orientation – adjusted to the fea-
ture lines.

Important:
Important Changing the profile orientation, make sure that the pro-
files do not overlap.

For the decklid define the profile orientation as is in Fig. 3.6:

Fig. 3.6

Modified profile orientation before confirming with OK

28
 Lesson 3: Profile Orientation

Having changed the profile orientation all along the addendum,

click on OK in the Direction dialog.

The addendum should be as is in Fig. 3.7:

Fig. 3.7

Addendum after manual modification of the profile–orientation

Modifying the Punch Opening Line

In the bumper area of the decklid, the distance between the punch
opening line and the part boundary must increase to integrate a
higher bar into this region.

Addendum Lines > PO width: Edit ...

Use the Curve editor to change the punch opening line, which
should be as in Fig. 3.8:

29
Lesson 3: Profile Orientation

Fig. 3.8

Modified punch opening line before confirming in the Curve editor

Having accepted the changes in the Curve editor, the addendum is

automatically adjusted to the new punch opening line.

If no characteristic line needs any further modifications, close the

window using the Dismiss button.

Modifying the Master–Profile

To receive a uniform punch impact in the visual region of the part, a
bar must be provided for the whole addendum. Define the modifi-
cation of the master–profile.

Note:
Note To see an entire view of the master–profile in the display, it is
sufficient to click with the middle mouse button into the profile win-
dow.

Select the profile template (Bar).

Click the right side of the horizontal dashed line with the left mouse
button (in the profile window) and move it to approximately 20 mm
bar height.

Set the option Bar in the area Heights to Bndr, to measure the
height of bar from the binder.

30
 Lesson 3: Profile Orientation

Enter the height of the bar:

Addendum Heights > Bar: 80

The master–profile should be as in Fig. 3.9:

Fig. 3.9

Master–profile with bar

In addition, some radii and angles of the master–profiles have to be

adjusted to meet the requirements of the addendum for the decklid.

Addendum Advanced > Die radius: 8 > Wall angle: 15 > Punch radius: 35 >CB
radius: 30 > Enter > Dismiss

Note:
Note Having entered this information, the respective changes can
be viewed in the profile window. Confirm each entry by pressing
the Return key.

Adjust the circle radius with the mouse: Click the respective circle
with the left mouse button and click and drag the mouse to size the
circle. The current value of the radius is indicated above the display.

Finally, a counter bar is integrated into the master–profile: Move the

lower horizontal line down as far as possible.

31
Lesson 3: Profile Orientation

The master–profile should be as in Fig. 3.10:

Fig. 3.10

Master–profile with bar and counter bar

Click on the Apply button to generate the addendum based on the

modified master–profile.

Apply Addendum

Plus–Parameter
The Plus parameters define a region of the addendum between the
profile parameters described above and the part boundary. The
Plus region determines the laid out flanges (for post operations). In
the case of the decklid, this is the region of the flange (hemming).

The Plus parameters are contained in the Advanced dialog.

Note:
Note Detailed information on the Plus parameters will be given in
Appendix 3.

For the flange of the decklid enter:

Widths > Plus: 10 > Heights > Plus: 5 > Apply Addendum

An additional step is added to the addendum (near the part bound-

ary).

32
 Lesson 3: Profile Orientation

Adding individual Profiles

In most of the cases an optimal addendum cannot be generated by a
master–profile only. Typically, an optimal addendum contains a
number of individual profiles. The generation of the individual pro-
files is an integral part of the work in DieDesigner.

For the decklid, eight individual profiles differing from the master–
profile have to be added:

First, add the profiles without any changes, i.e. they use the same
settings as the master–profile.

Addendum Add prf … > Select > Profile: 1 > Add

Add prf … > Select > Profile: 223 > Add
Add prf … > Select > Profile: 309 > Add
Add prf … > Select > Profile: 349 > Add
Add prf … > Select > Profile: 381 > Add
Add prf … > Select > Profile: 398 > Add
Add prf … > Select > Profile: 401 > Add
Add prf … > Select > Profile: 414 > Add

Tabs with the profile number of the new profiles are added to
Addendum page.

There are different procedures to generate and modify individual

profiles:

• Use the mouse to generate an individual profile based on

automatically generated profiles.
• The automatically generated profiles are numbered cir-
cumferentially. To insert a new individual profile, enter a
profile number.
• Individual profiles can be copied, moved and deleted
using the mouse: Click an individual profile with the right
mouse button, move the profile with the mouse button
held down and finally release the mouse button. Move an
individual profile outside the part to delete the profile.

33
Lesson 3: Profile Orientation

Modifying Individual Profiles

An individual profile must be selected before it can be modified.
Select the profile by clicking it in the main display or by clicking the
respective tab on the Addendum page. Selected profiles are shown
in yellow.

Change the profiles as described in the list below.

Prf 1 > as Master Addendum

Prf 223 > CB radius as small as possible (mouse)
Prf 309 > as Master
Prf 349 > Advanced > Punch radius: 40
Prf 381 > Advanced > CB radius: 39 > Punch radius: 44
Prf 398 > Advanced > CB radius: 55 > Punch radius: 60
Prf 401 > Advanced > CB radius: 52 > Punch radius: 52
Prf 414 > as Master

Apply

Fig. 3.11

Generated addendum based on individual profiles

34
 Lesson 3: Profile Orientation

Smoothing the Bar

The feature lines of the part proceed into the addendum. To
smoothen the regions of the addendum, change the bar height line.

Addendum Lines > Bar height > Edit ... > Change the line by moving or delet-
ing nodes until the result is as shown in Fig. 3.12

Procedure to change the bar height line:

• Click on a point (yellow) > Delete (to delete the point)

• Click on the line between two points to add a point
• Move a point with the right mouse button held down (z–
direction)

Fig. 3.12

Smoothed bar height line

Saving the Data

User interface File > Save

35
Lesson 4: From DieDesigner to Deep Drawing Simulation

3. 4 Lesson 4: From DieDesigner to Deep Drawing Simula-

tion

By the example of a cross member this lesson shows how to review a tool design gen-
erated with AutoForm–DieDesigner by means of a try–out simulation (in this case the
AutoForm–Incremental solver is used). Besides the functions used in the previous les-
sons, we describe how you can import a punch opening line and a binder surface. We
take advantage of the fully parameterized tool surfaces.

Fig. 4.1

Tool for a cross member

Creating a new Simulation

File > New > File name: lesson4 > OK User interface

Importing the Part Geometry

File > Import … > af > OK > Geometry gen-
Files: dd_lesson_04.af > OK erator

36
 Lesson 4: From DieDesigner to Deep Drawing Simulation

Generating the Part Boundary

Go to the Prepare page and generate the part boundary:

Prepare Apply

Boundary Fill
Before generating the addendum generate the boundary fill:

Bndry Add bndry fill … > Pick curve: Curve1 > OK

Define the roll radius:

Bndry fill roll radius: 100

Finally click on

Apply

Generating a Binder Surface with Auto–Binder

Accept the default setting with the exception of the drawing depth
and the profile orientation. Select Uniform to achieve a uniform
drawing depth over the whole part. Define the main curvature by
entering an angle with respect to the x–axis. A curved binder is pro-
posed by default in the Binder page.

Binder Auto > Drawing depth: Uniform > Profile orientation: > Angle: 90
> Apply

Generating the Addendum

The addendum for the part is generated now. Go to the Addendum
page and select the part boundary for the generation of the adden-
dum:

Addendum Add addendum ... > Pick curve: Curve3 > OK

Accept the default settings of the master–profile with the exception

of the punch opening width:

PO width: 50 > Apply

37
Lesson 4: From DieDesigner to Deep Drawing Simulation

The tool geometry is shown in Fig. 4.2:

Fig. 4.2

A first tool design

Modifying the Profile Orientation

The profile orientation has to be adjusted to the essential feature
lines of the geometry.

Select

Directions … Addendum

Modify the profile orientation as shown in Fig. 4.3 and finally click
on

OK

38
 Lesson 4: From DieDesigner to Deep Drawing Simulation

Fig. 4.3

Modified profile orientation before confirming with OK

The addendum should be as in Fig. 4.4:

Fig. 4.4

Addendum after manual modification of the profile–orientation

39
Lesson 4: From DieDesigner to Deep Drawing Simulation

Modifying the Punch Opening Line

Smooth the punch opening width (distance between part boundary
and punch opening line) on the Addendum page:

Lines ... > PO width > Edit > Global mod > Convex: 1 > OK Addendum

The following tool is shown in the main display:

Fig. 4.5

Addendum after smoothening the punch opening line

Importing the Punch Opening Line

A punch opening line generated in a CAD system can be imported
into AutoForm–DieDesigner. The orientation is left unchanged after
importing the punch opening line. Import the punch opening line
into the Curve editor:

Model > Curve manager > File > Import > af > OK > User interface
Files: dd_lesson_04_pol.af > OK > Dismiss

Lines ... > PO width: Copy from … > Pick curve > Curve1 > OK Addendum

40
 Lesson 4: From DieDesigner to Deep Drawing Simulation

Fig. 4.6

Addendum with imported punch opening line

Smoothen the Punch Radius Characteristics

The punch radius characteristics have to be smoothened. Rotate the
part as shown in Fig.4.7 and select:

Addendum Lines ... > Bar height > Edit

Change the bar height line as shown in Fig. 4.8.

Note:
Note Select all nodes along the line (Shift
Shift key – right mouse button)
and press the Smooth button several times (until the bar height line
has been smoothened sufficiently).

To close the Curve editor click on:

OK

41
Lesson 4: From DieDesigner to Deep Drawing Simulation

Fig. 4.7

Modifying the bar height line

Fig. 4.8

Addendum after smoothening the bar height line

Importing a Binder Surface

Besides the generation of a binder surface using the DieDesigner
functions, you can also import a binder surface generated in a CAD
system. Different CAD formats are available.

Delete the existing binder surface:

Delete > Delete Binder

Import the binder surface on the Binder page:

Import ... > af > OK > Files: dd_lesson_04_binder.af > OK Binder

42
 Lesson 4: From DieDesigner to Deep Drawing Simulation

Define a Shift value for the binder position, which is greater than
the value entered in Min shift.

Binder Binder position > Shift: 25

Go back to the Addendum page to adjust the addendum to the new

binder:

Addendum Apply

The modified tool is shown in Fig. 4.9:

Fig. 4.9

Addendum with imported binder surface

Preparing and Starting the Incremental Deep Draw-

ing Simulation
Finally, the tool design is checked by a try–out simulation. To do so,
process information has to be entered into the Input generator.

User interface Model > Input generator > OK

Note:
Note The tool setup can only be changed on the Prepare page of
the Geometry generator.

Title Accept the default settings.

Tools The tool geometries on the Tools page of the Input generator are
adapted automatically. The Geometry generator distinguishes
between the registers Part, Fill, Addendum and Binder.

43
Lesson 4: From DieDesigner to Deep Drawing Simulation

The objects are assigned automatically to the respective registers:

• die: Part + Fill + Addendum + Binder

• punch: Part + Fill + Addendum
• binder: Binder

Define the columns for the binder:

binder > Columns: None Tools

On the Blank page, a simple rectangular blank with the dimensions

500 x 1300 is defined.

Outline > Rectangle … Blank

Fig. 4.10

Blank outline - Rectangle

Blank outline - Rectangle > Length X: 500 > Length Y: 1300 > OK

Fig. 4.11

Definition of a rectangular blank

44
 Lesson 4: From DieDesigner to Deep Drawing Simulation

On the Process page, determine the direction of gravity:

Process gravity > Gravity: Upwards > die: Stationary

Start the deep drawing simulation normal the usual settings (as
described in the AutoForm–Incremental lessons):

Input generator Job > Start Simulation ... > Save > Start

At any time during the simulation run, the current state of the cal-
culation can be read into the main display:

File > Reopen

After a short time the results for thinning are available:

Fig. 4.12

Progress of calculation

45
Lesson 5: Creating a Binder Surface with Auto–Binder and Manual–Binder

3. 5 Lesson 5: Creating a Binder Surface with Auto–Binder

and Manual–Binder

Creating a binder surface with AutoForm DieDesigner can be done with the module
Auto–Binder and with the module Manual–Binder. Importing the binder surface is possi-
ble. The binder surface imported from CAD or generated with Auto–Binder can be
optimized with the module Manual–Binder. By changing the binder surface the existing
addendum is dynamic adjusted. The binder surface created or changed with DieDe-
signer can be exported in several CAD–formats.

Fig. 5.1

Binder surface created with the module Manual–Binder

Creating a new Simulation

File > New > File name: lesson5 > OK User Interface

Reading the Part geometry (Left half of the part)

For this lesson the left half of the tailgate is input in the af–format.

File > Import > af > OK > Files: dd_lesson_05.af > OK Geometry Gen-
erator
Definition of the symmetry plane
The right half of the part geometry has to be generated by symme-
try, in order to generate the full drawing die. For that purpose the
symmetry plane has to be defined at first.

Symmetry / double … Prepare

46
 Lesson 5: Creating a Binder Surface with Auto–Binder and Manual–Binder

With the second icon of the geometry types, you specify that only
half of the symmetric geometry has been imported. This half will be
mirrored about the specified symmetry plane (x-z-plane).

Symmetry, half input > x-z-plane > y: 0 > OK

Now the part boundary is generated.

Prepare Apply

The input task on the Prepare page is now completed.

Creating the binder surface with the module Auto–

Binder
The module Auto–Binder allows you to create a first concept for the
binder surface very quickly. The characteristic of the binder surface
can be influenced by many adjustment parameters. The form and
position of the parts as well as a constant drawing depth is consid-
ered. The binder surface can also be created as single curved/
warped or double curved/warped. The input is very often carried
out with a sliding bar in the window. Thus the necessary character-
istic of binder specific parameters can be more or less realized.

In general the procedure is work in an iterative manner. The first

concept of the Auto–Binder is generated with the default values.
After this, single parameters are modified until the desired binder
surface is created. The distance from part to binder surface (= draw-
ing depth) is displayed as colored contours on the part geometry, in
order to analyze the current binder surface for uniformity in draw-
ing depth.

Change to the Binder page. The following parameters are suitable

for this tailgate.

Binder Auto
Std > Max bndry slope: 10.0 deg > Angle diff.: 10.0 deg
Adv > Min flange width: 250.0 > Apply

The display of the drawing depth can be turned on and off in the
menu Display of the Geometry Generators:

Geometry Gen- Display > Drawing depth

erator

47
Lesson 5: Creating a Binder Surface with Auto–Binder and Manual–Binder

The range of the color for the drawing depth can be changed in the
same menu. Press the Return key after inserting of the following
values.

Display > Ranges > Manual: > Min: 0 > Max: 80 > Return >
Dismiss

Fig. 5.2

Binder surface created with the module Auto–Binder

Modifying a binder surface with the module Man-

ual–Binder
The binder surface imported from CAD or generated with Auto–
Binder can be greatly improved with the module Manual–Binder.
Binder–profiles can be added.

Creating Binder–profiles (Sections of the binder surface)

The binder–profiles are created and modified with the Curve editor.
At least two crossing binder–profiles have to be generated.

Manual Binder

The following menu for the binder modification appears:

48
 Lesson 5: Creating a Binder Surface with Auto–Binder and Manual–Binder

Fig. 5.3

Menu for the manual change of the binder surface

Binder Add

An additional window appears. Manual modification of the binder–

profiles (as described below) has to be confirmed with OK in this
window.

Remark:
Remark In a few cases, you can use this window to specify the pro-
jection curves on the part (projection of the binder–profiles on the
part in z–direction) for the basis of the binder profiles. This option has
to be activated before creating the binder–profiles. (This option is
not used for this tailgate.)

49
Lesson 5: Creating a Binder Surface with Auto–Binder and Manual–Binder

Fig. 5.4

Question before creating the binder–profiles

The current binder surface is shown with a circumferential yellow

boundary line in the main display. The binder surface will be
enlarged by selecting the points in the corner.

Fig. 5.5

Enlarging or reducing of the binder surface by moving the corner

points of the boundary lines.

Indicate with the right mouse button two points on two opposite
boundary lines in order to create a new binder–profile.

Remark:
Remark In order to change the direction or position of the binder–
profiles keep the right mouse button pressed and move the end
points of the profile along the boundary line.

If the Shift key is pressed the binder–profiles are created exact hori-
zontal or vertical. Take this procedure and create two crossing
binder–profiles as shown in Fig. 5.6.

50
 Lesson 5: Creating a Binder Surface with Auto–Binder and Manual–Binder

Fig. 5.6

Two crossing binder–profiles

Confirm the end of the insert in the window Add/edit profiles with
OK.

The warning indicates that the existing binder surface (imported

CAD–surface or generated with Auto–Binder) will be replaced.

Confirm with OK.

If you rotate the model in the main display, you can see blue, green
and yellow lines. The lines have the following meaning:

• Blue lines: The created binder–profiles on the binder sur-

faces.
• Green lines: Binder–profiles projected in z–direction on the
part geometry.
• Yellow lines: The last selected (with the mouse or on the
Manual–Binder page) binder–profile together with the pro-
jection lines on the part.

51
Lesson 5: Creating a Binder Surface with Auto–Binder and Manual–Binder

Fig. 5.7

Meaning of the blue, green and yellow lines

Changing the Binder–profiles

Binder–profiles can be modified and/or added, in order to improve
the binder surface.

The binder–profile has to be first selected, in order to modify it.

Select binder–profiles (by picking out with the right mouse button Manual–Binder
in the main display or with the left mouse button directly on the
Manual–Binder page) > Edit

Remark:
Remark Rotate the part to the position shown in Fig. 5.7.

The points on the red lines can now be moved in the z–direction
with the active Curve editor. By clicking on the line, new points are
generated, which can also be moved.

If the modified line has the desired form, press OK in the Curve edi-
tor and the modified binder surface and the colored displayed
drawing depth is immediately updated.

Also all existing binder–profiles can be changed at the same time.

Edit all ...

Confirm this modification with Yes.

Additional binder–profiles can be created with the button Add. The

above described procedure can be repeated for the new profiles.

To delete binder–profiles press the button Delete.

52
 Lesson 5: Creating a Binder Surface with Auto–Binder and Manual–Binder

Additional Options
Additional options are available on the Manual–Binder page:

Fig 5.8

Description of the further options on the Manual–Binder page:

• Box / Edit grid: Adjusting the size of the binder surface

• Orientation: The binder surface can be rotated around the
x–axis (+- 90 degrees)
• Position of reference binder: Use the arrow keys to move
the binder surface in z–direction relative to the part. This
function is used for the analysis of the theoretical punch
impact. In the main display, you can see both the real
binder surface and the reference binder surface.
• From contact: Maximal distance between part and refer-
ence binder surface
• From closed: Distance between reference binder surface
and the real binder surface
• Binder position (Shift): Shift of the binder surface in verti-
cal direction
• Min. shift: Smallest distance in z–direction between binder
surfaces and part. Define the value in the field Shift.

53
Lesson 5: Creating a Binder Surface with Auto–Binder and Manual–Binder

• Drawing depth: Greatest distance in z–direction between

binder surfaces and part
• Trim with binder surface: Cuts the part with the binder
surface considering the offset. This function can be used for
the generation of pre–forming tools.

Exporting the Binder Surface

The binder surfaces generated with Auto–Binder or Manual–Binder
can be exported as CAD faces in IGES or VDAFS format:

Geometry generator > File > Export surfaces > Binder > Binder sur-
face > IGES (af oder VDAFS) > OK

Exporting Binder Profiles

The binder profiles generated with Auto–Binder can be exported in
af format or as CAD faces in IGES or VDAFS format:

Geometry generator > File > Export binder profiles > Format: IGES
(or VDAFS) > OK

Further processing in this lesson is analogous to processes

described in Lesson 3.

Saving the Data

File > Save User interface

54
 Lesson 6: Defining of the Drawing Direction (Tip)

3. 6 Lesson 6: Defining of the Drawing Direction (Tip)

There are very powerful automatic functions and analysis capabilities to define the
optimal drawing direction on the Tip page. In addition the possibilities to choose one
out of several automatic functions, the user can tip the part around the x–, y– and z–
axis to a more useful drawing direction. This can also be done with a local tipping cen-
ter. Moreover a drawing direction designed in a CAD–system can be imported and the
drawing direction defined with DieDesigner can be exported to handle it within a
CAD–system.

Important:
Important Please note that in AutoForm, the z–axis is always the
drawing direction. The functions on the Tip page rotate the geome-
try in a way that the z–axis will be the drawing direction.

Creating a new Simulation

User Interface File > New > File name: lesson6 > OK

Reading the Part geometry (Left half of the part)

For this lesson, the left half of the tailgate (in the af format) is used.

Geometry Gen- File > Import > af > OK > Files: dd_lesson_06.af > OK
erator
Definition of the symmetry plane
Prepare The right half of the part geometry has to be generated by symme-
try, in order to generate the full drawing die. For this purpose, the
symmetry plane has to be defined at first.

Symmetry / double …

With the second icon of the geometry types you specify that only
half of the symmetric geometry has been imported. This half will be
mirrored about the specified symmetry plane (x-z-plane).

Symmetry, half input > x-z-plane > y: 0 > OK

Now the part boundary is generated.

Prepare Apply

The required tasks on the Prepare page are now completed.

55
Lesson 6: Defining of the Drawing Direction (Tip)

Defining the optimal drawing direction

The part is rotated to the drawing position on the Tip page.

Fig. 6.1

The functions on the Tip page to define the drawing direction

Remark:
Remark You will find a complete description of the functions of the
Tip page in the Appendix 2.

Colored display of the drawing angle for the part

The backdraft or drawing angle for the current drawing direction is
shown colored on the part in the main display of the Tip page.

Two types of displays can be chosen:

56
 Lesson 6: Defining of the Drawing Direction (Tip)

Display Backdrafts
Tip Geometry generator > Display > Backdrafts

The backdraft of the part is displayed in red in the main display.

Fig. 6.2

Backdrafts:
Backdrafts Display of the backdraft

Meaning of the colored areas:

• Safe: Drawing angle greater than 3 degrees

• Marginal: Drawing angle between 3 degrees and 0 degrees
• Severe: Backdraft under 0 degrees

Remark:
Remark The default value for the limit Severe/Marginal
Severe Marginal and Mar-
ginal/Safe
ginal Safe can be changed by the user.

57
Lesson 6: Defining of the Drawing Direction (Tip)

Display Drawing angle

Geometry generator > Display > Drawing angle

The angle between part geometry and the z–axis is displayed in the
main display.

Fig. 6.3

Display of the current Drawing angles

The displayed colored range can be changed in the Geometry Gen-

erator in the menu Display under Ranges.

For this lesson, please choose Backdrafts display as described

above.

Defining of the Tipping center

In the most cases, it is useful to choose the tipping center close to the
part or tool geometry.

Tipping center: > Define Tip

The coordinates for the desired tipping center are entered in the dia-
log Tipping center.

58
 Lesson 6: Defining of the Drawing Direction (Tip)

Fig. 6.4

Defining of the Tipping center

For this tailgate, input the following values:

Coordinates: > X: 5130.0 > Y: 0.0 > Z: 1460.0 > OK

Automatic functions to define the tipping direction

It is recommended to start with the functions Average normal, Min
draw depth and Min backdraft to generate a suitable drawing
direction.

• Average normal: Generates the average normal vector of

the part surfaces (or selected surfaces; in the main display:
Options > Pick faces) and takes this vector as z–axis (=
drawing direction).
• Min draw depth: Drawing position with minimal drawing
depth
• Min backdraft: Drawing position with minimal backdraft

These three functions generate in the most cases a reasonably good

drawing direction.

Manual rotating in the drawing position

In cases the drawing direction calculated by automatic functions is
not satisfactory a manual tipping (Incremental tipping / moving) of
the part geometry around the x–,y– or z–axis has to be carried out.

Please pay attention that corresponding to the selected part type

(Symmetry, Double part ...) the tipping around equivalent axis is
suspended.

Election of the desired rotation axis

Tip About: > Y-axis

Insert of the rotation angle

Tip by degrees: > 55.0

59
Lesson 6: Defining of the Drawing Direction (Tip)

Gradual tipping of the part with the inserted rotation angle (Incre-
mental tipping).

rotate: > - Tip

Analyzing the available backdraft–free drawing directions

The theoretically available backdraft–free drawing directions are
shown in a 2D diagram (Backdraft diagram).

Plot Tip

Two colored lines are displayed in the diagram.

Fig. 6.5

Backdraft–diagram
Backdraft

Explanation of the Backdraft–diagram

The center of the axis is the current drawing direction. The distance
between the axis center and the lines represents the backdraft–free
angle to the drawing direction. The horizontal axis shows the rota-
tion around the y–axis and the vertical axis shows the rotation
around the x–axis.

This means, that a rotation around the y–axis (horizontal line in the
diagram) is backdraft–free as long as the rotation angle is inside the
red line. The red line represents the limit angle Severe/Marginal
and the green line the limit angle Marginal/Safe for the presenta-
tion of the backdrafts.

Remark:
Remark Each tipping operation of the part with the above
described functions (automatic or manual) is accompanied by a
dynamic update of the Backdraft–diagram.

Saving the Data

File > Save User Interface

60
 Lesson 7: Modification of Product and Tool Geometries

3. 7 Lesson 7: Modification of Product and Tool Geome-

tries

The following product and tool geometry modification features of AutoForm–DieDe-

signer are illustrated in this lesson: trimming of product geometry at/near the part
edge, trimming off of geometry from the interior of product, filleting of sharp edges,
local and global overcrowning of product geometry, and creation of features such as
stiffening beads on product geometry. Further, modification of tool geometry through
global overcrowning as well as through local geometry change is also illustrated.

Fig. 7.1

Tool with modified part geometry and addendum

Create a new simulation file:

User interface File > New > File name: lesson7 > OK

Import product/part geometry:

Geometry gen- File > Import > af > OK > Files: dd_lesson_07.af > OK
erator
The imported part geometry mesh is now displayed in the main dis-
play.

Boundary and control curves that will eventually be used in this les-
son will be imported first. Control curves are usually created manu-
ally using the Curve editor. The option of importing these curves is
used here in order to reduce the complexity and length of this exer-
cise. However, in order to limit the complexity and the duration of

61
Lesson 7: Modification of Product and Tool Geometries

this exercise, these curves were created and saved previously using
the Curve editor and the Geometry generator.

Model > Curve manager > File > Import… > IGES > Use all > Keep User interface
orientation > OK > Files: dd_lesson_07_crvs.igs > OK
Program: afmesh_3.1 > OK > Show used > Dismiss

Pre–processing of part geometry by trimming at

part edge and by trimming off a restruck tab in the
interior of part
Fig. 7.2

Prepare page

Trimming at part edge/boundary

In order to be able to use the Outer Trim functionality, it is neces-
sary to first generate the part boundary.

Apply Prepare

62
 Lesson 7: Modification of Product and Tool Geometries

The objective here is to eliminate the step in the upper right corner
of the part geometry by „trimming“ it off using Outer Trim. Zoom
closer to this corner of the part geometry and select the following
function:

Prepare Outer trim > Edit ...

Fig. 7.3

Part geometry (and part boundary line) showing the area requiring
modification

First delete all points on the part boundary around the geometry
feature to be trimmed off. Pick the first point on the segment (of the
part boundary) to be deleted with the right mouse button – the
point that is leftmost on the horizontal edge of the step. Then, hold
the Shift key down and pick the bottom–most on the vertical edge
of the step. All points on the part boundary between these two are
automatically selected and displayed in yellow. Delete all these
points using the Delete key on the keyboard (or by using the Delete
button in the Curve editor, confirming the action by clicking Delete
again).

Fig. 7.4

The selected points are displayed in yellow

63
Lesson 7: Modification of Product and Tool Geometries

Modify the resulting chopped edge on the boundary by adding two

points on the boundary (right mouse button), one each at the end of
the horizontal and vertical straight edges on the part. Positions of
these points may then be adjusted if necessary so they sit on the
edge. Then click on the straight segment between the two new
points with the right mouse button while holding the Ctrl key. This
curves the segment, and provides a representation of the desired
part edge. Once these changes are complete, click on OK in the
Curve editor dialog box to confirm the modification.

Fig. 7.5

Part geometry before and after confirmation of changes using OK

Trimming off geometry from the interior of part

Undesirable geometry features (areas that are formed in flanging or
restrike operations, but not in the draw die) may be eliminated
using the Inner trim function. In this lesson, the assembly tab at the
center of the part will be trimmed off. Zoom into this area to create
an inner trim line.

Inner trim > Add ... Prepare

64
 Lesson 7: Modification of Product and Tool Geometries

Create a rectangular outline around the tab.

Fig. 7.6

The portion of part geometry enclosed within the inner trim line will
be deleted.

Confirm selection by clicking OK.

65
Lesson 7: Modification of Product and Tool Geometries

Global filleting of all sharp edges on part geometry

Switch over to the Fillet page in order to create new fillets.

Fig. 7.7

The Fillet page

Identify and fillet sharp edges as described below:

• Check: Check for radii less than the value specified to iden-
tify sharp edges
• OK: Accept the set of identified edges

Global fillet radius > Global radius: 3.00 > Apply Fillet

Following filleting, it is possible to display either the filleted (Fil-

leted geometry) or the unfilleted (Edged geometry) geometry in the
main display.

66
 Lesson 7: Modification of Product and Tool Geometries

Fig. 7.8

Filleted geometry

Fig. 7.9

Edged geometry

Filleting of individual edges – constant fillet value

If it is necessary to create fillets of different radii along different
edges of the part geometry, these individual edges have to be iden-
tified and fillet radius values (constant over the edge or variable)
have to be specified, in addition to the global radius values. Those
edges that were identified as sharp, and for which no additional fil-
let radius specifications are made will all be filleted to the global
radius value. Use the button Add line... at the bottom of the Fillet
page to identify specific edges and to specify radius values on these
edges.

67
Lesson 7: Modification of Product and Tool Geometries

Add line ... opens an alert box with the message: Mark radius con- Fillet
trol edge. Finish with double click.

Click at the starting point of the desired edge with the right mouse
button. Then let go of the mouse button, and drag the cursor along
the edge. The selected edge gets progressively highlighted along its
length in yellow. Click once with the right mouse button at the end
point on the edge to end selection.

Hint:
Hint If it happens that the edge being marked runs through an
intersection with other edges (for example at the corner of a rect-
angular box) or through a sharp turn, progressive edge marking
may become ambiguous when going over the intersection or the
sharp turn. Then, click at a point on the edge marked thus far to
confirm selection up to that point, and proceed along the curve or
branch to be followed, clicking points on the desired edge as it
runs out of the intersection or curvature. In areas like this, it
becomes essential to click points before and after the intersection
to mark edges in an unambiguous fashion.

Mark an edge, as described above, for the purpose of this exercise.

Specify constant fillet radius on this edge – select the Constant

radius option, and specify a fillet radius value of 8 mm. Click on the
Apply button to generate the specified radius along that edge (and
global fillet radii elsewhere on the part geometry).

Fig. 7.10

Specifying a constant fillet radius on an edge

Filleting of individual edges – variable fillet value

Using the option Add line ... and the procedure described above,
select yet another edge.

Specify variable fillet values along this edge as described below:

Variable > Add point ... Fillet

68
 Lesson 7: Modification of Product and Tool Geometries

Pick points along the newly selected edge at which local radius val-
ues will be specified eventually. Confirm selections by clicking on
the OK button.

Enter the radius values at the selected points in the table displayed
under Variable fillet radius.

Line 2 is to be filleted with radius values of 5 mm and 8 mm.

Fig. 7.11

Specifying variable fillet radius values

Fig. 7.12

Two edges with local fillet radius values different from that specified
globally: the upper edge has a constant value and lower edge has
a variable radius.

Modification of part geometry: Modify P

Switch to the Modify P page for related functionality and set up.

Using functionality available on this page, it is possible to modify

part geometry by global overcrowning as well as by adding local
detail. Further, gaps and holes can also be filled, and the filled areas
can be edited/modified in this page

69
Lesson 7: Modification of Product and Tool Geometries

Add overcrown: Overcrowning the part geometry (local and glo-

bal)
This function may be used to overcrown a selected portion of the
part geometry (Region boundary) on the basis of user–specified
control curves/points (Control curves/points) so that part curvature
in the selected region is increased to forestall the eventual effect of
springback and resulting poor part quality. In this exercise, the flat
floor of one of the two long channels is overcrowned (Fig. 7.12).

Add overcrown > Curve editor: Cancel > Region boundary: Copy Modify P
from … > Pick curve: Curve2 > OK

Modify direction allows the user to specify the direction along

which the overcrown needs to be applied.

Control curves / points, together with the index options (Free, Par-
allel or Plateau), allow the specification of the type of overcrown:

• Free: The mesh of the overcrowned geometry runs through

the specified control curves/points.
• Parallel: Control curves and points are projected on to the
part geometry, and are re–positioned by the value speci-
fied under Shift, in the direction specified under Modify
direction. The overcrowned mesh then runs through the
repositioned control curves/points as a curved surface.
• Plateau: Control curves and points are projected on to the
part geometry, and are re–positioned by the value speci-
fied under Shift, in the direction specified under Modify
direction. The overcrowned mesh then runs through the
repositioned control curves/points as a flat surface.

In the present exercise, control curves are read in, and an overcrown
is established using the index Free:

Add curve ... > Curve editor: Cancel > Copy from … > Pick curve: Modify P
Curve1 > OK > Apply

Fig. 7.13

Overcrowned channel floor, region boundary and control curves

70
 Lesson 7: Modification of Product and Tool Geometries

Add detail: Create a stiffening bead in the part geometry

This function allows the creation of detail such as beads on the part
geometry. To accomplish this, it is necessary to identify that portion
of the part geometry that needs to be modified by specifying a
boundary curve (Region boundary):

Modify P Add detail > Curve editor: Cancel > Region boundary: Copy from
... > Pick curve: Curve1 > OK

This closed curve is expanded 10 mm outward:

Region boundary: Edit … > Global mod > Expand: 10 > OK

Control curves / points, together with the index options (Free, Par-
allel or Plateau), allow the specification of the detail to be added to
part geometry:

Hint:
Hint The index (Parallel
Parallel and Plateau)
Plateau has a different function under
Add hole/detail from that under Add overcrowning.

• Free: The mesh of the overcrowned geometry runs through

the specified control curves/points.

• Parallel: The modified mesh then runs through the reposi-

tioned control curves/points as a curved surface. Control
curves and points may be repositioned by the value speci-
fied under Shift, in the direction specified under Modify
direction.
• Plateau: The modified mesh then runs through the reposi-
tioned control curves/points as a flat surface. Control
curves and points may be repositioned by the value speci-
fied under Shift, in the direction specified under Modify
direction.

In the present exercise, control curves will be read in, and a bead
generated using the index setting Parallel:

Modify P Add curve ... > Curve editor: Cancel > Copy from … > Pick curve:
Curve2 > OK

Parallel > Shift: -10 > Apply

71
Lesson 7: Modification of Product and Tool Geometries

Fig. 7.14

Bead generated using Add detail

Add hole/All holes: filling up holes and gaps in the part geometry
Two options are available for filling holes:

• Add hole allows a single, specified hole to be filled, and

the filled patch to be edited/modified.
• All holes allows all holes on part geometry to be filled;
however, the fill patches are not modifiable.

The following outlines the use of both these functions in turn:

Add hole > Pick curve: Curve3 > OK Modify P

Control curves / points determine the geometry of the surface filling

the specified hole.

Add points > select two points within the boundary of the hole >
OK

Plateau > Shift: -5 > Apply

72
 Lesson 7: Modification of Product and Tool Geometries

Fig. 7.15

Fill patches of hole filled using Add hole

All remaining holes may now be filled in one step:

Modify P All holes > Apply

Creation of binder and addendum

Creating a binder
Move over to the Binder page to create a new binder.

Binder Auto > Profile orientation > Angle: 0 > Apply

Creating an outer addendum

Switch to the Addendum page to generate addendum.

Addendum Add addendum ... > Pick curve: Curve1 > OK

Width > PO: 60 > Apply

73
Lesson 7: Modification of Product and Tool Geometries

Modification of tool geometry – Modify T

Change to the Modify T page to carry out this modification.

This page contains functionality (Add overcrown and Add detail)

to modify geometry of the entire tool – part, binder and addendum.
This functionality is therefore basically the same as that available in
the Modify P page.

In the present lesson, we will create a small take–up bead on the

punch, and then overcrown the entire tool geometry.

Add detail: Creating a take–up bead on the addendum

Read in the boundary of the region that needs to be modified:

Add detail > Curve editor: Cancel > Region boundary: Copy from Modify T
… > Pick curve: Curve3 > OK

The contour of the detail to be added may be defined using a con-

trol curve:

Add curve ... > Curve editor: Cancel > Copy from … > Pick curve:
Curve4 > OK

Select the option Free and click on the Apply button to create the
take–up bead geometry.

74
 Lesson 7: Modification of Product and Tool Geometries

Fig. 7.16

Detail (take–up bead) added to punch geometry

Add overcrowning: overcrowning the entire tool geometry

To avoid (or minimize) springback problems following forming of
the part, the entire tool geometry may be overcrowned as described
below: As a first step, define the boundary of the region on the tool
geometry – as a rectangular outline on the binder area – that needs
to be overcrowned.

Hint:
Hint Hold the Ctrl key down when clicking points to create the
region boundary: this ensures that all segments on the boundary
are straight sided. If points are clicked without holding the Ctrl key
down, spline segments are fit between these points.

Modify T Add overcrowning > Hold Ctrl key down and pick 4 points outlin-
ing the entire punch geometry > OK
Add curve ... > Pick 4 points within the above outline that enclose
the part geometry> OK

Parallel > Shift: 10 > Apply

75
Lesson 7: Modification of Product and Tool Geometries

Fig. 7.17

Overcrowned geometry of the tool

Exporting fill patches and faces of the newly created geometry

(Add detail)
Fill patches as well as detail patches created in AutoForm–DieDe-
signer may be exported in CAD–compatible format (IGES or
VDAFS). Call up the following option in Geometry generator to
accomplish such an export:

Geometry generator > File > Export surfaces > Fill/Detail > IGES >
OK

Saving the data and inputs created

File > Save User interface

76
 Lesson 8: A Tool with Inner Binder and Inner Addendum

3. 8 Lesson 8: A Tool with Inner Binder and Inner Adden-

dum

For panels such as body sides and doors (inner and outer), it becomes essential to con-
trol metal flow both from the outside and from the inside (interior openings). For this
reason, it becomes necessary to create binder and addendum both on the outside
and in the inside. This lesson demonstrates the creation of inner tool entities – inner
binder and inner addendum using AutoForm–DieDesigner.

Create a new simulation file:

User interface File > New > File name: lesson8 > OK

Import product/part geometry:

Geometry gen- File > Import > af > OK > Files: dd_lesson08.af > OK
erator
The imported part geometry mesh is now displayed in the main dis-
play. It is half of a complete part geometry.

Locating the binder surface relative to the part geometry

From the Tool setup box in the Prepare page, select the icon on the
right; this selection ensures that the binder surface (to be generated
subsequently) lies on the flange side of the part geometry.

Completion of the full (symmetric) geometry as well

as its boundary
Defining a symmetry plane
Symmetry / double > Symmetry, half input > x-z – plane: 0 > OK

Hint:
Hint The Preview option may be used to review the complete
geometry before creating it in the main display.

Generating the boundary of the complete part geometry

In order to subsequently create addendum geometry between the
part edge and binder surface, it is necessary to generate the Part
boundary:

Prepare Generate part boundary: Apply

77
Lesson 8: A Tool with Inner Binder and Inner Addendum

Fig. 8.1

Complete part geometry along with symmetry plane

Filling up of holes
Holes may be filled using the functionality of the Modify P page.

All holes > Apply Modify P

Reading in the binder surface

A binder surface that is already available may be read in (imported) Binder
from Binder page.

Import... > af > OK > Files: dd_lesson_08_binder.af > OK

78
 Lesson 8: A Tool with Inner Binder and Inner Addendum

Creation of inner and outer addendum

Move to the Addendum page.

Inner addendum
First select the boundary curve for the inner addendum:

Addendum Add addendum... > Curve2 > OK

Specify typical parameters for the master profile of the inner adden-
dum:

Widths > Plus: 10.00

Heights > Bar: 0.00 > Tngl
Advanced > Punch radius: 12.00 > Die radius: 15.00 > Dismiss >
Apply

Fig. 8.2

Inner binder and inner addendum

79
Lesson 8: A Tool with Inner Binder and Inner Addendum

Outer addendum
First select the boundary curve for the outer addendum:

Add addendum... > Curve1 > OK Addendum

Specify typical parameters for the master profile of the inner adden-
dum:

Widths > Plus: 10.00

Advanced > Punch radius: 12.00 > Die radius: 15.00 > Dismiss >
Apply

Geometry of the inner and outer addenda thus created may be

modified and fine–tuned using already familiar options such as
editing of lines (PO–width, Bar–height), directions and individual
profiles.

Fig. 8.3

Initial tool geometry (based on master profile parameters as speci-

fied above)

80
 Lesson 8: A Tool with Inner Binder and Inner Addendum

Repositioning of inner and outer binders in the z–

direction
The draw depths in the interior and exterior of a tool containing
inner and outer binders/addenda may be varied independent of
each other. This is done by repositioning the inner and outer binder
in the z–direction.

Outer binder
To move the outer binder, switch to the Binder page:

Binder Shift: 10.00 > Enter

Inner binder
The inner binder may be moved in the z–direction by specifying a
shift in the Inner 1 subpage of the Addendum page.

Addendum Binder… > Binder shift: -10 > Dismiss > Apply

Saving the data and inputs created

User interface File > Save

81
Lesson 9: Development of a tool for double attached parts

3. 9 Lesson 9: Development of a tool for double attached

parts

This lesson illustrates the application of AutoForm–DieDesigner for developing a tool to

stamp a left–side and a right–side part double attached. A symmetry plane is speci-
fied to mirror the left–side geometry (imported) to create the right–side geometry.
Then the two halves are rotated into draw position, following which the area between
the left– and right–side parts is filled. A binder surface is generated, and an addendum
created to complete the development.

Fig. 9.1

Tool for stamping left– and right–sides double attached.

Create a new simulation file

File > New > File name: lesson9 > OK User interface

Importing the part geometry (left–side)

The part geometry (left–side) for this lesson is in af–format. The
right–side part is a mirror image of the left–side and is generated
within AutoForm.

File > Import > af > OK > Files: dd_lesson9.af > OK Geometry gen-
erator
Selecting and inserting the flange faces into the Flange register
Flanges on this part are to laid out, and formed after the draw oper-
ation. Therefore these flange faces do not need to be used in devel-
oping the draw die geometry.

Select the flange faces of the imported geometry using the Shift– Prepare
right mouse button combination (inclusive of the radii along the
long straight edge of the part geometry).

82
 Lesson 9: Development of a tool for double attached parts

Fig. 9.2

Left–side part geometry with the flange faces highlighted in yellow

Prepare > Define objects: Flange

Press the Flange button to add the selected faces to the correspond-
ing register. This turns off the display of the selected faces in the
main display. These faces may be displayed by clicking the button
Display flange.

Prepare Generate part boundary: Apply

This generates the boundary of the geometry remaining in the Part

register (all faces other than those in the Flange register).

Defining a symmetry plane

Specify a symmetry plane to mirror the left–side part geometry. It is
only later that the two parts will be tipped (Tip page) into draw
position.

Prepare Symmetry / double ...

83
Lesson 9: Development of a tool for double attached parts

Fig. 9.3

Defining geometry type and symmetry plane

For parts that are mirror–images of each other, the geometry type
option Left/right, half input needs to be selected.

In the present exercise, an x–z–plane with a symmetry location at y:

-780 mm needs to be specified.

Hint:
Hint The Preview option may be used to review the complete
geometry before creating it in the main display.

Upon clicking on the OK button, the left– and right–side parts are
displayed together in the main display. Further, the boundary of the
complete is automatically generated and is also displayed.

84
 Lesson 9: Development of a tool for double attached parts

Fig. 9.4

Left– and right–side part geometries

Tipping the left– and right–side parts into draw posi-

tion
Move to the Tip page.

In all, five options (Double attached) are available to tip part geom-
etries for which double attached tools need to be developed. These
options provide specific means of translating and rotating the left–
and right–side parts relative to each other. In the present case,
wherein the left– and right–sides have already been imported, only
three options are available (only three of the five buttons are active).

85
Lesson 9: Development of a tool for double attached parts

Fig. 9.5

The three available tipping options

tip left, sync. right

The left–side part is rotated and/or translated, and the right–side is
rotated and/or translated in mirror–image fashion about the speci-
fied symmetry plane.

tip right, sync. left

The right–side part is rotated and/or translated, and the left–side is
rotated and/or translated in mirror–image fashion about the speci-
fied symmetry plane.

tip all
Left– and right–side parts are simultaneously translated and/or
rotated; this does not permit arbitrary rotations.

The option under the third button is ideal for our case. Tip

Double attached > tip left, sync. right

86
 Lesson 9: Development of a tool for double attached parts

Rotating and moving the double–part geometry into draw posi-

tion
The parts are simultaneously first rotated in the sequence y–axis, x–
axis, z–axis, and then the separation between the parts is adjusted,
keeping in mind the minimum trim distance as well as subsequent
restrike to form the flange. To obtain the final orientation depicted
in Fig. 9.6, the following rotation–translation sequence needs to be
followed.

Rotation
Tip Y-axis > by degrees: 75.0 > rotate: -
X-axis > by degrees: 10.0 > rotate: +
Z-axis > by degrees: 2.0 > rotate: +

Translation
by dx dy dz: 0.00 / 5.00 / 0.00 > move: -

Fig. 9.6

Parts in draw position

Filling holes
Filling the holes in part geometry in the Modify P page.

Modify P All holes > Min size: 1.5 > Max size: 300.0 > Apply

87
Lesson 9: Development of a tool for double attached parts

Filling the Gap between the two Parts

The gap between left– and right–side parts needs to be filled in
before the addendum can be generated. Similar to the generation of
an outer fill (Lesson 2), the geometry between double attached parts
is filled by using the concept of roll cylinders. By selecting an appro-
priate roll radius the user may exert some influence on the outer
edge of the fill faces.

Add double fill > Double fill roll radius: 100.00 > Bndry fill roll Bndry
radius: 300.00 > Apply

Fig. 9.7

Fill surfaces between left– and right–side parts

Modifying fill faces using Control curves

Without any effort to keep the resultant modification realistic, the
methodology/procedure for modifying automatically generated fill
faces is illustrated in the following. This procedure is typical of
what the user would follow to create features such as draw bars or
take up beads on the fill area between parts.

Modifications are carried out by creating and using any number of

control curves over the fill area; these control curves determine the
shape of the modified fill faces. Control curves may be created and
modified using the Curve editor.

Control curves: Add Bndry

88
 Lesson 9: Development of a tool for double attached parts

Using the Curve editor (Edit mode: Free), create a control curve,
and then modify it using the Edit mode: Vertical to outline and cre-
ate a bead in the draw direction.

Please attempt to recreate the two curves depicted in Fig. 9.8.

Hint:
Hint The following edit mode options are available when creating
or modifying curves using the Curve editor.

• Horizontal: Points have freedom to move in the x–y plane

only.
• Vertical: Points have freedom to move in the z–direction
only.
• Free: Points have freedom to move in any arbitrary direc-
tion.
• Snap: Points snap to available curves.

While control curves may intersect one another, it is important to be

careful when locating these intersection points.

Upon completion of input, and upon clicking on the Apply button,

the modified fill face is generated.

Fig. 9.8 depicts the bead created between the two parts as also the
corresponding control curves.

89
Lesson 9: Development of a tool for double attached parts

Fig. 9.8

Modified fill faces containing bead

Creating a binder using Auto–Binder

Switch to the Binder page.

Auto Binder

Specify the following parameters to generate an Auto–Binder for

the double attached tool:

Drawing depth: Uniform > Profile orientation: 0 or 90 deg > Sur-

face profile > Max bndry slope: 10.0

Adv > Profile shape: Type 1 > Min flange width: 150.0 > Apply

Creating an addendum
Switch to the Addendum page.

Add addendum > Pick curve: Curve 1 > OK > Apply Addendum

It is possible, using the several options available in the Addendum

page, to appropriately modify and fine–tune the addendum geome-
try starting from the initial geometry based on the master profile.
That however is not the focus of Lesson 9.

90
 Lesson 9: Development of a tool for double attached parts

Exporting fill faces

The fill faces created between the two parts of a double attached
tool in AutoForm–DieDesigner is exportable in CAD–compatible
IGES– or VDAFS–format:

Geometry generator > File > Export surfaces > Fill/Detail > IGES >
OK

Saving the data and inputs created

User interface File > Save

91
Appendix 1: Useful Tips and Techniques

3. 10 Appendix 1: Useful Tips and Techniques

• Part on binder
• Trim using binder surface

AutoForm Engineering is constantly developing new functionality

in AutoForm–DieDesigner. Some of this functionality was not in
place at the time of deployment of the current version of the soft-
ware (version 3.1). This section provides tips on how to extract
additional functionality and utility from the current version over
and beyond what it is designed to provide.

This appendix outlines a systematic approach to tackling the two

important and useful issues listed above. Unlike the lessons in this
workshop, this outline is not based on specific sample geometry.

The tips outlined here assume general familiarity with the Auto-
Form–DieDesigner features described in the various lessons.

Part on binder
Very often a subarea of the part geometry is put on the binder sur-
face. We describe the procedure in AutoForm–DieDesigner step–
by–step.

Part–1:
Part surfaces that will be on binder may be selected and stored in
the Binder register in the Prepare page, and the boundary is gener-
ated for the remaining faces.

92
 Appendix 1: Useful Tips and Techniques

Fig. 10.1

Preprocessing elements such as filling up of holes, tipping etc. may

be carried out as described in the lessons.

Part–2:
Hint:
Hint Version V3.1 offers the Part on binder option only when gener-
ating a binder surface in the Binder page (Auto–Binder
Auto–Binder as well as
Manual–Binder).
Manual–Binder

Part on binder using Auto–Binder

Binder Auto
Binder position > Shift: 0.0

Hint:
Hint Since the Binder Shift value refers to the distance between
binder surface and the faces that have to laid on binder. This value
therefore needs to be set to 0.0 to achieve precise placement of
these faces on the binder surface.

Select the option Part on binder (Integrate binder faces) in the

Binder page (Auto–Binder).

Fig. 10.2

Part on binder option

The significance of the option Boundary: free/fixed is explained in

the following:

93
Appendix 1: Useful Tips and Techniques

A binder surface is first generated internally (not obvious to user)

based on the Auto–Binder input parameters. This surface is not
fully integrated with the intended Part on binder faces of the part.
Then, transition faces are generated between the latter faces, and the
boundary of the internally generated (primary) binder surface. The
contour of these transition faces may be controlled through selec-
tion of the more appropriate (to the geometry on hand) of the two
options: Free or Fixed (boundary of binder surface).

• Free: The boundary of the primary binder surface may

move in the z–direction. Tangents at the edge of the pri-
mary binder have the freedom to change.
• Fixed: The boundary of the primary binder surface is fixed
in the z–direction. Tangents at the edge of the primary
binder do not have the freedom to change.

Fig. 10.3

Part flange surfaces are integrated into the binder surface.

Part on binder using Manual–Binder

The Auto–Binder surface may be manually modified.

Manual Binder

The Part on binder (Integrate binder faces) option is also available

in the Manual–Binder page.

94
 Appendix 1: Useful Tips and Techniques

The required binder profiles are first generated.

Manual-Binder > Profiles: Add ...

It must be kept in mind that the binder profiles being edited do not
have to lie entirely on the modified binder surface. Even if it hap-
pens that the profile lines do not coincide with the Part on binder
faces, the modified binder will be seen to integrate these faces.

Part–3:
In the current version of AutoForm–DieDesigner (version 3.1), only
completely closed addendum geometries may be created, and no
break is possible in the area where part faces lie on binder. The user
need to ensure smoothness and continuity of the tool geometry in
these areas by specifying appropriate addendum profile parameters
(small radii, etc.).

Trim using binder surface

For part geometries with large depths (door inner panels), it may
not be possible to develop a feasible draw die and process based on
a single draw stage. In such cases, it may be necessary to develop
multiple draw/re–draw stages to achieve robust feasibility. The cur-
rent version of AutoForm–DieDesigner (version 3.1) provides two
functions that facilitate the development of such tools. It is possible
to cut the part geometry at any desired depth of part by proper
positioning of the binder surface at that depth. Following this, the
usual procedure may be applied to complete the addendum of this
first stage tool. Likewise, tools for any number of draw/re–draw
stages may be developed. This trim functionality in conjunction
with the options to modify part or tool geometry (Modify T and
Modify P: to modify radii, etc.) allows the creation of good tools for
the different stages.

Part–1:
Generate a binder surface in the Binder page.

Hint:
Hint Here too the Part on binder option may be used if appropriate
to the part being worked on.

95
Appendix 1: Useful Tips and Techniques

Fig. 10.4

Binder generation

Part–2:
The Trim with binder surface option may be activated in the Binder
page after specifying a value in the Offset field (for e.g., 10.0). This
has the effect of separating the trimmed part and binder by the
specified distance to facilitate generation of an addendum.

Fig. 10.5

Trimming part geometry using the binder surface, with an offset

value of 10 mm.

Part–3:
Addendum geometry may be generated and fine–tuned as required
in the Addendum page.

96
 Appendix 1: Useful Tips and Techniques

Fig. 10.6

Completed tool

97
Appendix 2: The Tip Page

3. 11 Appendix 2: The Tip Page

Here, all functions which are used on the Tip page are summarized.

Fig. 11.1

Double attached
This area is only active if on the Prepare page the working of a dou-
ble attached part was chosen.

98
 Appendix 2: The Tip Page

The following options are available:

• Use tip left to apply all settings of the Tip page on the left
side of a double part. This option is available for parts of
the type Left/right, full input or Two parts according to
the Prepare page.
• Use tip right to apply all settings of the Tip page on the
right side of a double part. This option is available for parts
of the type Left/right, full input or Two parts according to
the Prepare page.
• Use tip left, Sync. with right to apply all settings of the Tip
page on the left side of a double part. The transformations
(rotation and translation) are applied on the right part also,
however, mirrored in symmetrical fashion with respect to
the plane of symmetry. This option is available for parts of
the type Left/right, half input or Left/right, full input
according to the Prepare page.
• Use tip right, Sync. with left, to apply all settings of the
Tip page on the right side of a double part. The transfor-
mations (rotation and translation) are used on the left part
also, however, mirrored in symmetrical fashion with
respect to the plane of symmetry. This option is available
for parts of the type Left/right, half input or Left/right,
full input according to the Prepare page.
• Use tip all to apply all settings of the Tip page on both
sides of a double part. While doing so, the changes of part
orientations continue to be synchronized with each other;
they are used as a single part. This option is available for
parts of the type Left/right, half input or Left/right, full
input or two parts according to the Prepare page.

Tipping center
You can specify on a new centre of rotation with this function. If you
use a double part, the label on the button changes in accordance
with your selection in the area Double attached:

• The button is Define left ..., if you use tip left or tip left,
Sync. with right.
• The button is Define right ..., if you use tip right or tip
right, Sync. with left.
• The button is Define ..., if you use tip all.
• Enter the x, y and z coordinates of the new centre of rota-
tion. The option Center of gravity chooses the center of
gravity of the part or selected surfaces as rotational centre.

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Total tipping
• Average normal: Determines the average normal vector of
the part or of selected surfaces and defines it as the new z–
axis (= drawing direction).
• Min draw depth: Determines the drawing position to min-
imize the drawing depth.
• Min backdraft: Drawing position with minimized back-
draft
• Screen axes: Defines the drawing direction perpendicular
to the actual screen axes.
• Set draw dir ...: Using this dialog you define the drawing
direction by the definition of a straight line. You should
use Copy from curve ..., to define the direction based on an
existing curve.
• Reference ...: The part is tipped in accordance with a cur-
rently used geometry.
• Sync: Both parts of a double part are synchronized. This
option is only available for parts of the Type Two parts
according to the Prepare page.
• Reset: Deletes all transformations and restores the original
z–axis of the geometry as drawing direction.
• Import/Export: With this sub–dialog, one can write or read
the actual transformation matrix in a file and apply it on
the actual part.

Incremental
Incremental tipping/moving
This is used to perform manual rotation or translation of the part
around the x–, y– or z–axis. Use the buttons +/- to carry out the cor-
responding transformation. All changes are directly visible if you
have chosen Plot before.

Note:
Note For geometries of the types Symmetry, half input, input Symmetry,
full input and Left/right, half input as well as Left/right, full input in
connection with Tip all, all not all rotational axes are available.
Because the plane of symmetry is always parallel to the z–axes in
AutoForm, rotations are only possible around the z–axis and the
normal of the symmetry axis.

• Axis: Use this function to tip a part around a user defined

axis. The corresponding button is Define left ..., Define
right ... or Define ..., depending on the option that was
chosen in Symmetry/Double attached on the Prepare
page. Specify the start and end points of the new axis or
choose an existing line using additional options available.

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Note:
Note The button Define ... is called Show for the cases Symmetry,
half input
input, Symmetry, full input and Left/right, half input and Left/
right, full input in combination with Tip all.
all In this case, the normal to
the plane of symmetry is inserted.

Backdraft diagram
Using the middle point of the axes as a starting point, the circular
lines in the diagram show the angle to the actual drawing direction.
The horizontal axis outlines the rotation around the y–axis, the ver-
tical axis the rotation around the x–axis.

If the part is tipped around the y–axis (horizontal axis in the dia-
gram), it stays free of backdrafts at rotational angles at which the
origin lies within the red curve. The colored curves correspond to
the limit angles Severe/Marginal and Marginal/Safe for the
description Backdraft.

Remark:
Remark The backdraft diagram is constantly updated with any
rotations of the part with the functions described above.

Current transformation
This area shows the sum of all used transformations. At the rota-
tion, the angle around the x–, y– and z–axes is shown. This
sequence must be retained in the same order. For the translation,
values in x–, y– and z–directions are given. This information is
available for left and right parts. The reference point is always the
original part position.

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Appendix 3: The Addendum Page

3. 12 Appendix 3: The Addendum Page

The Addendum page of the Geometry Generator contains all func-

tions for the generation or modification of an outer or several inner
addenda.

Figure 12.1

The Addendum page (one outer and two inner addenda)

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 Appendix 3: The Addendum Page

Structure of the Addendum page

The tabs on the top of the Addendum page represent the user
defined outer addendum (Outer) and any additional inner addenda
(Inner...) if available.

The graphic window shows the master–profile or the active individ-

ual profile together with the end sections of the part and binder
geometry. All radii can be modified by picking and dragging the
circle line with the mouse. The current value of the corresponding
radius is shown at the top left of the diagram. The total length–of–
line of the profile is displayed on the bottom right of the display.
Zooming and dragging is possible using AutoForm’s common
mouse and keyboard operations.

Input fields for the profile parameter (radii, angle, length and
heights), the Advanced ... button for additional parameters and six
icons for predefined profile templates are arranged below the dia-
gram.

The functionality of the buttons in the bottom area is described in

the following.

Important buttons on the Addendum page

• Add addendum: Generate an outer or if necessary an inner
addendum.
• Delete addendum: Delete the current addendum.
• Add prf ...: Generate an user defined profile.
• Delete prf: Delete an user defined profile.
• Lines ...: Edit the punch opening line (PO width), bar
height line and counter bar height line (CB height) or
import of the punch opening line.
• Directions ...: Change the profile directions.
• Binder ...: Translation of the inner binder surface (in draw-
ing direction).

The master profile

The master profile represents the primary reference profile. It is
used to define beads, radii and angles that are valid for the most
parts of the addendum. For different distances between part and
binder along the addendum only heights and lengths of the master
profile are varied.

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Appendix 3: The Addendum Page

The user defined profiles

In most cases it is not possible to obtain an optimal addendum by
using the master profile only. An optimal addendum usually con-
sists of several user defined profiles. The generation and modifica-
tion of this individual profiles is an essential part of the work with
DieDesigner.

The parameter of the profile definition

Profile widths
Width of the Plus area representing an additional region of the part Plus
boundary for the accommodation of flange areas.

Width of the bar with the options: Bar

• Min: minimum bar width

• Max: maximum bar width (step)
• Free: free defined bar width within the range of the Min
and Max values

Distance of the punch opening line to the part geometry with the PO
options:

• Min: minimum distance depending on the specified radii

and angles
• Free: punch opening line (freely definable)
• Tngl: tangential elongation of the part towards the binder
surface

Profile heights
Height of the Plus area representing an additional region for the Plus
accommodation of flange areas

Height of the bar with the options Bar

• Part: Height is measured with respect to the part.

• Bndr: Height is measured with respect to the binder sur-
face.
• Tngl: Height is measured with respect to the tangential
elongated part surface.

Position of the CB height line (counter bar) with respect to the part CB
boundary

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 Appendix 3: The Addendum Page

With the options:

• Free: counter bar freely definable

• Off: no counter bar

Note:
Note By pressing the M key the values specified for the master pro-
file are actually selected.

The Advanced ... dialog

Additional parameters for the definition of the profiles can be
edited by pressing the Advanced ... button.

Figure 12.2

Advanced profile parameters

Changing the advanced profile parameter

The parameters can be edited either by keyboard input in the corre-
sponding text fields or by picking and dragging of the dashed lines
in the diagram with the mouse.

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Appendix 3: The Addendum Page

The following figures show all profile parameters:

Figure 12.3

The two horizontal, dashed lines represent the bar height and the
counter bar height, respectively.

Figure 12.4

The two vertical, dashed lines represent the position of the punch
opening line (PO
PO width
width) and the bead width (Bar
Bar width).
width

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 Appendix 3: The Addendum Page

Figure 12.5

Radii of the profiles: Part radius

radius, Counter bar radius,
radius Punch radius,
radius
Die radius

Figure 12.6

Profile angles: CB angle

angle, Wall angle
angle, Bar angle

Plus parameter
With the Plus parameter, an additional area of the addendum
defined by the previously described parameters and the part
boundary is controlled. The Plus area characterizes the part of the
addendum used for the accommodation of flanges. In case of a
decklid, this is the part of the flange (hemming).

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Appendix 3: The Addendum Page

Note:
Note The parameter of the Plus area has an effect for Widths Plus
values greater than 0.0 only.

The Plus area is not designed to model beads in the addendum.

This may cause spurious results from the interpolation between the
profiles.

Figure 12.7

The parameter of the Plus area: Plus width,

width Plus height,
height Edge angle,
angle
Edge radius,
radius Flange angle
angle, Flange radius

The profile templates

The profile templates are used for a quick pre–definition of special
profile properties (with / without bead, ...) for specific areas of a
complex addendum. By picking a template button the options are
set to the corresponding default values.

The following templates are available:

This template causes a tangential transition from the part boundary

to the binder surface. Bar width, Bar height and CB height are
deactivated.

Tngl, fixed PO

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 Appendix 3: The Addendum Page

This template causes a minimum distance of the punch opening line

to the part boundary. Bar width, Bar height and CB height are
deactivated.

Min PO

This template allows an arbitrarily definable distance of the punch

opening line to the part boundary. The height of the bead (Bar) is
measured from the tangential elongation of the part surface. The
bead width (Bar width) is set to Min and therefore is not active. CB
height is switched off (Off) and therefore is not active as well.
Tngl, free PO

This template allows an arbitrarily definable distance of the punch

opening line to the part boundary. The height of the bead (Bar) is
measured from the part surface (Part). In some cases it is suggested
to switch on the option Bndr to measure the bead height with
respect to the binder surface so that an uniform punch contact can
Smooth be achieved. Bar width is set to Min and CB height is switched off
(Off) and therefore are deactivated.

This template generates a maximum bead width (Bar width is set to

Max), which cause a step in the addendum. The distance of the
punch opening line to the part boundary is freely definable.

The height of the step (Bar) is measured with respect to the part sur-
Step face (Part). In some cases it is suggested to switch on the option
Bndr to measure the bead height with respect to the binder surface
so that an uniform punch contact can be achieved. CB height is
switched off (Off) and therefore is not active.

This template is similar to the Smooth template, but contains a

counter bar.

Bar

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Appendix 3: The Addendum Page

110