Ansys Forming Tutorials

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Table of Contents
1. Introduction ............................................................................................................................................ 1
2. Box Tutorial ............................................................................................................................................. 3
2.1. Get Started ....................................................................................................................................... 3
2.1.1. Launch Ansys Forming ............................................................................................................ 3
2.1.2. Download Input Files ............................................................................................................... 4
2.1.3. Create a New Forming Project .................................................................................................. 4
2.2. Project Settings ................................................................................................................................ 5
2.2.1. Configure the Process .............................................................................................................. 5
[Link]. Configure General Settings .............................................................................................. 5
[Link]. Configure Tip Parameters ................................................................................................. 7
[Link]. Plan Process Operations .................................................................................................. 8
[Link].1. Set the Stamping Angle ........................................................................................ 10
[Link].2. Set the Center of Die ............................................................................................. 10
2.2.2. Blank Settings ........................................................................................................................ 11
[Link]. Import Blank Geometry ................................................................................................. 11
[Link]. Select Blank Geometry ................................................................................................... 12
[Link]. Select Blank Material ..................................................................................................... 15
[Link]. Define Remaining Blank Values ...................................................................................... 17
2.2.3. Operations Settings ................................................................................................................ 18
[Link]. Set Up the Lay-in Station (D-10) ..................................................................................... 19
[Link]. Set Up the First Trimming Station (T-20) ......................................................................... 42
[Link]. Set Up the Second Trimming Station (T-30) .................................................................... 47
[Link]. Set Up the Flanging Station (F-40) .................................................................................. 52
[Link]. Set Up the Third Trimming Station (T-50) ........................................................................ 60
[Link]. Verify the Operations Settings ........................................................................................ 62
2.2.4. Run the Project ...................................................................................................................... 62
2.3. Postprocessing Analysis .................................................................................................................. 64
2.3.1. View a Simulation Summary ................................................................................................... 65
2.3.2. View Deformation Results ....................................................................................................... 65
2.3.3. View Edge Draw-In ................................................................................................................. 67
2.3.4. Evaluate Springback ............................................................................................................... 67
2.3.5. View and Export a Tonnage Prediction Plot ............................................................................. 68
2.3.6. Export a Mesh of the Final State .............................................................................................. 70

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List of Figures
2.1. The Box Tutorial Project ........................................................................................................................... 3
2.2. Forming User Interface Window .............................................................................................................. 4
2.3. Process General Parameters .................................................................................................................... 6
2.4. Solution Accuracy ................................................................................................................................... 7
2.5. Process Tip Parameters ............................................................................................................................ 8
2.6. Operations Tab of the Process Task Panel ................................................................................................. 9
2.7. Imported Curve .................................................................................................................................... 12
2.8. Design-1 Task Panel .............................................................................................................................. 13
2.9. Blank Geometry Defined ....................................................................................................................... 15
2.10. Design-1 Task Panel with Selected Geometry ....................................................................................... 15
2.11. Material Viewer Showing CR4 .............................................................................................................. 16
2.12. Blank Definition Table ......................................................................................................................... 17
2.13. Operations Buttons in the Ribbon ....................................................................................................... 18
2.14. An Operation Task Panel ...................................................................................................................... 18
2.15. Trim/Pierce Task Panel ......................................................................................................................... 42
2.16. The Flanging Operation Task Panel ...................................................................................................... 52
2.17. Runner, Ready ..................................................................................................................................... 63
2.18. Runner, Completed ............................................................................................................................. 64
2.19. Simulation Summary ........................................................................................................................... 65
2.20. Deformation, State # 1 ......................................................................................................................... 66
2.21. Deformation, State #64 ........................................................................................................................ 66
2.22. In-Flow Draw-In .................................................................................................................................. 67
2.23. Springback Evaluation ........................................................................................................................ 68

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Chapter 1: Introduction
Ansys Forming is a dedicated application for LS-DYNA press-forming simulations. It seamlessly integrates
preprocessing, solving, and postprocessing in a user-friendly interface. A template-based approach enables
you to easily define complex sheet metal forming processes, and set up multi-stage forming simulations.
You can add a new forming stage, define additional forming processes, and evaluate the simulation
results while the job is running.

For more information, see the Forming User's Guide.

This document contains tutorials that will help you get started setting up forming projects, simulating
the forming process, and analyzing simulation results.

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Chapter 2: Box Tutorial
In this tutorial, you will define a project to simulate the forming of a simple box.

Figure 2.1: The Box Tutorial Project

Begin by starting the Forming software and creating the project. Then, configure the process, blank,
and operations settings. Finally, run the simulation and analyze results.

2.1. Get Started

Before you can define the details of your project and run the simulation, you must start the software
and open an empty new project.

2.1.1. Launch Ansys Forming

Once installed, the software is available on the Start menu on your computer.

If, for some reason, it is not listed on the Start menu, it is installed as:

Program Files\ANSYS Inc\V252\forming\[Link]

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Box Tutorial

Start the application. The basic window with no open projects looks like this:

Figure 2.2: Forming User Interface Window

2.1.2. Download Input Files

Ansys has prepared a collection of shapes, curves, and surfaces that will enable you to complete this
tutorial without creating these designs yourself. Download the Forming_Tutori-
al_Box_Files.zip archive from the Ansys customer site.

2.1.3. Create a New Forming Project

Once the software is open, create a new project.

1. Click New Project in the ribbon to open the New Setup dialog.

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2. Enter a Name and Location for storing the project and its files.

3. Leave the Type and Unit set to their defaults.

4. Click OK.

The software creates the project file and the analytics folder in the location you chose with the name
you entered.

2.2. Project Settings

Before you can do an accurate simulation, you must create an accurate model of the process, and define
all settings correctly. Begin by setting up the main process settings, define the material blank that will
be processed, refine the definitions of each operation in the process line, then modify simulation settings
and run the simulation.
2.2.1. Configure the Process
2.2.2. Blank Settings
2.2.3. Operations Settings
2.2.4. Run the Project

2.2.1. Configure the Process

Click the Process tab in the main toolbar to open the Process ribbon and the Process task panel.

You will use this panel to configure the main, high-level settings of the project.

[Link]. Configure General Settings

Use the General tab of the Process task panel to define basic simulation parameters.

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Box Tutorial

Figure 2.3: Process General Parameters

1. Click the General tab in the Process task panel if it is not already selected.

2. Click the Note field and enter some descriptive text for the project. In the future, this note will
help you remember the purpose of this project.

3. You can use the Flow Direction drop-down menu in the Press section of the panel to define
the feeding direction according to the actual feeding direction of the mold.

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The default +X direction is good for this tutorial, and does not need to be changed.

4. In the Settings section of the panel, you can use the accuracy drop-down menu to configure
the solver accuracy. Click the triangle to the right of Solution to open the accuracy drop-down
menu.

Figure 2.4: Solution Accuracy

• Accurate provides a good balance between accuracy and solution speed.

• Fast provides a rapid solution with the loss of some accuracy.
• VeryAccurate provides the highest accuracy, but takes the longest time to run.

The default Accurate setting is good for this tutorial, and does not need to be changed.

[Link]. Configure Tip Parameters

Use the Tip tab of the Process task panel to define the stamping direction of the blank.

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Figure 2.5: Process Tip Parameters

1. Click the Tip tab in the Process task panel.

2. Click the triangle to open the Base drop-down menu.

3. Choose User Defined from the menu.

The default Tip settings are good for this tutorial, and do not need to be changed.

[Link]. Plan Process Operations

Click the Operations tab in the Process task panel to define the processes performed and the
angle of the sheet during each operation.

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Figure 2.6: Operations Tab of the Process Task Panel

The tutorial project has five operations: one "Draw/Stretch" operation, three "Trim/Pierce" operations,
and one "Form Trim/Flange/Restrike" operation. All tipping angles are relative to the process co-
ordinate system.

1. The first Draw/Stretch operation was added when you created the project. Leave it in place as
"D-10".

2. Click the Add Operation ( ) button.

3. The new operation is added as a Draw/Stretch operation, but you want a Trim/Pierce operation.

a. Click the down arrow on the "D-20" operation's description.

b. Choose Trim/Pierce from the drop-down menu.

4. Shortcut this process by clicking the triangle that is attached to the Add Operation ( )
button, and choosing Trim/Pierce from the drop-down menu to create operation "T-30".

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Box Tutorial

5. Add a "Form Trim/Flange/Restrike" using either method to create operation "F-40".

6. Add one more "Trim/Pierce" operation, "T-50".

The operations list should now look like this:

If you accidentally added an extra operation, remove it by clicking the delete ( ) button next to
it.

If the operations are in the wrong order, move any operation by dragging and dropping it within
the list.

[Link].1. Set the Stamping Angle

On this tab of the Process task panel, you can also define the stamping angle of each operation.
To do so:

1. Select an operation in the table by clicking the operation's label.

2. Choose Process or Global from the Relative To drop-down menu.

3. Check the box next to Angles.

4. Enter U, V', and W" values (in degrees).

5. Click Update.

The default Tipping settings are good for this tutorial, and do not need to be changed.

[Link].2. Set the Center of Die

On this tab of the Process task panel, you can also define the center of the die for each operation.
To do so:

1. Select an operation in the table by clicking the operation's label.

2. Check the box next to Origin.

3. Enter X, Y, and Z values to define the origin point.

4. Click Update.

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The default Center of Die settings are good for this tutorial, and do not need to be changed.

2.2.2. Blank Settings

Click the Blank tab in the main toolbar to open the Blank ribbon and the Design-n task panels.

You will use this panel to configure the shape and material of the sheet, plate thickness, and rolling
direction.

[Link]. Import Blank Geometry

For this tutorial, you will import a geometry file that defines the shape of the blank.

1. In the ribbon, click Import to open the Import task panel.

2. In the Curve section of the panel, click the Import curve ( ) button to open a file
browser.

3. Navigate to the directory that contains the provided input files.

4. Select the file: blank [Link]

5. Click Open.

6. Verify that "blank [Link]" is now listed in the Curve section of the Import task panel.

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Box Tutorial

7. Click Close to return to the Design-1 task panel.

The curve file you imported is now listed in the Feature Tree, is shown in the Geometry Window,
and is available to be selected as a blank.

Figure 2.7: Imported Curve

[Link]. Select Blank Geometry

Now that the curve is available in the project, you can select it to define a blank.

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Figure 2.8: Design-1 Task Panel

1. In the Design-1 task panel, in the Definition table, click Select… to open the Define Blank
by Curve task panel.

2. Make sure that the By Curve radio button is selected.

3. In the Pick Options section, make sure that Cursor is selected and the Trace check box is
checked.

4. In the graphics window, move the cursor along the edge of the imported curve until the outline
of the rectangle is traced, then click to select the outline.

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5. In the Outlines section of the panel, click Set.

6. In the Outlines section of the panel, click the available "Outline" to highlight it and confirm
that the full shape is outlined.

7. Click the triangle next to Mesh Options to expand that section.

8. Check the box next to Element Size to enable editing that value, and enter 6 in the field.

9. Click Apply to define a blank using that outline.

10. Click Close to return to the Design-1 task panel.

A short designator is displayed in the table where it previously showed "Select", and the table cell
background is green.

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Figure 2.9: Blank Geometry Defined

[Link]. Select Blank Material

Now that the geometry of the blank is defined, you can define the blank's material.

From the Material Library task panel, you can copy a library material into the project, import a
material definition that is not in the library, export a material definition to a file, and define a new
material using properties. The material used for this project is not in the library, so you will import
it.

Figure 2.10: Design-1 Task Panel with Selected Geometry

1. In the Design-1 task panel, in the Definition table, click No Mat. to open the Material Library
task panel.

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2. Click the Import Material ( ) button.

3. Use the file browser to navigate to where the tutorial input files are stored, and open the
[Link] file. The material's properties are displayed in the Material Viewer.

Figure 2.11: Material Viewer Showing CR4

4. Review the material properties, then click Save+Assign.

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 Project Settings

The material is now saved to the project and assigned to the blank.

[Link]. Define Remaining Blank Values

Finally, you may define the default rolling angle, blank thickness, and friction coefficient values.

Figure 2.12: Blank Definition Table

For the purposes of this tutorial, the default values are suitable and do not need to be modified.
Should you need to modify them in the future, follow this process:

1. To set the rolling angle of the blank:

a. Click in the fifth column of the table.

b. Enter a new angle for the rolling direction of the sheet (default = 0.0).

c. Press Enter.

d. Click Update.

2. To set the component thickness of the blank:

a. Click in the sixth column of the table.

b. Enter a new thickness (default = 1.0).

c. Press Enter.

d. Click Update.

3. To set the lubricated friction coefficient of the blank:

a. Click in the field next to Lub. Coeff..

b. Enter a new coefficient (default = 0.12).

c. Press Enter.

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d. Click Update.

The part produced in this tutorial is not symmetrical, so there is no need to set the Blank Symmetry.

2.2.3. Operations Settings

Click the Operations tab in the main toolbar to open the Operations ribbon and access detailed
task panels for each of the operations in the process.
[Link]. Set Up the Lay-in Station (D-10)
[Link]. Set Up the First Trimming Station (T-20)
[Link]. Set Up the Second Trimming Station (T-30)
[Link]. Set Up the Flanging Station (F-40)
[Link]. Set Up the Third Trimming Station (T-50)
[Link]. Verify the Operations Settings

Figure 2.13: Operations Buttons in the Ribbon

The operations shown are the ones you defined in Plan Process Operations (p. 8). Click any operation
button in the toolbar to view that operation's details in a task panel.

Figure 2.14: An Operation Task Panel

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[Link]. Set Up the Lay-in Station (D-10)

In the Operations ribbon, click D-10 to enter the draw/stretch settings interface. Here, you will
import curves and surfaces for the process tools, use these to create tools for the operation, define
settings for each tool such as movement and force, and check

The first setting of this operation that must be defined is the bias of the tool body. There are two
ways to bias the tool body in an operation. One way is to bias the tool body before importing. The
other way is to bias it in Ansys Forming. If you have already biased the tool body before importing,
select Already Have Offset and click Apply. If you are importing a reference tool body, you must
manually define the offset of the tool body on the other side of the Blank.

1. The tool body for D-10 has not already been biased, so define the tool surface offset manually.

a. Click the D-10 button in the ribbon to open the task panel.

b. In the D-10 task panel, click the OP Setting ( ) button to open the OP Setting task
panel.

c. Click the radio button for Define Offset.

When using Define Offset, if you are importing a tool body that is the upper die, then you
must generate the tool body of the lower module, and you only need to check Lower Tool(s).
If you import a tool body for the lower die, you must generate a tool body for the upper
module, and you only need to check Upper Tool(s).

d. Check the box for Upper Tool(s).

e. Set the upper tool offset to 1 times blank thickness.

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When the upper tool is generated, this setting will offset the tool body by the distance of
1 material thickness.

f. Click Apply to save the changes.

g. Click Close to return to the D-10 task panel.

2. Import the tool bodies required for this operation.

a. In the ribbon, click Import to open the Import task panel.

b. In the Surface section of the panel, click the Import surface ( ) button to open a
file browser.

c. Navigate to the directory that contains the provided OP10 input files.

d. Select all IGES files that match the pattern op10*.igs.

e. Click Open.

As they are imported, the polygons and lines of the surfaces are inspected, mainly to
check whether there are missing faces, few faces, or distortion of the polygons.

f. Verify that "op10 [Link]", "op10 [Link]", and "op10 [Link]" are now listed
in the Surface section of the Import task panel.

Note:

Ansys recommends that you do not import the tool bodies of all operations at
one time when setting up the analysis, especially when setting up complex
projects with many operations.

Import the tool bodies of each operation when setting up that operation. Im-
porting items in sequence makes it more convenient to quickly find the required
tool body, eliminate the interference of other process bodies, and avoid selecting
the wrong tool body.

3. Import the lance line required for this operation.

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a. In the Curve section of the panel, click the Import curve ( ) button to open a file
browser.

b. Navigate to the directory that contains the provided OP10 input files.

c. Select the IGES file lance [Link].

d. Click Open.

e. Verify that "lance [Link]" is now listed in the Curve section of the Import task panel.

f. Click Close to return to the D-10 task panel.

4. Add a cutting tool to the operation.

a. Click triangle in the +Tool ( ) button in the settings table to open the menu.

b. Choose +Cutting Tool from the menu.

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5. Define the die for the operation..

a. In the D-10 task panel, click Die in the table to highlight it and open the Die section.

b. Before continuing, limit the graphics window to show only the die surface.

In the Feature Tree, uncheck everything except for "op10 [Link]".

This hides all other curves and surfaces.

c. In the Die section of the task panel, click the Select… button in the third column to
open the Define Die by Surface task panel.

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d. In Pick Options, click Window if it is not already selected.

e. In the Graphics Window, click and drag the selection border around the surface to select
it as the tool body.

f. Click Apply to set this surface as the die.

g. Click Close to return to the D-10 task panel.

6. Define the binder for the operation..

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a. In the D-10 task panel, click Binder in the table to highlight it and open the Binder
section.

b. Before continuing, limit the graphics window to show only the binder surface.

In the Feature Tree, uncheck everything except for "op10 [Link]".

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This hides all other curves and surfaces.

c. In the Binder section of the task panel, click the Select… button in the third column
to open the Define Binder by Surface task panel.

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d. In Pick Options, click Window if it is not already selected.

e. In the Graphics Window, click and drag the selection border around the surface to select
it.

f. Click Apply to set this surface as the binder.

g. Click Close to return to the D-10 task panel.

7. Define the punch for the operation..

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a. In the D-10 task panel, click Punch in the table to highlight it and open the Punch
section.

b. Before continuing, limit the graphics window to show only the punch surface.

In the Feature Tree, uncheck everything except for "op10 [Link]".

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This hides all other curves and surfaces.

c. In the Punch section of the task panel, click the Select… button in the third column
to open the Define Punch by Surface task panel.

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d. In Pick Options, click Window if it is not already selected.

e. In the Graphics Window, click and drag the selection border around the surface to select
it.

f. Click Apply to set this surface as the punch.

g. Click Close to return to the D-10 task panel.

8. Define the cutting tool for the operation.

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a. In the table, right-click the cutting tool you added an choose Rename from the menu.

b. Set the tool name to Lance tool and click OK.

c. In the Graphics Window, use the Feature Tree to hide all other tool bodies, and display
only the "lance [Link]" curve.

d. In the D-10 task panel, click Lance tool in the table to highlight it and open the Lance
tool section.

e. In the Lance tool section, click the Create tool component ( ) button to open the
Pick Curve task panel.

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f. In the Pick Curve task panel, click Window if it is not already selected.

g. In the Graphics Window, click and drag the selection border around the curve to select
it.

h. Click Close to return to the D-10 task panel.

i. In the Graphics Window, use the Feature tree to display only the lance line curve and
the blank.

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j. In the task panel, next to Mark the area to keep, click None to open the Pick Single
Point task panel.

k. In the Graphics Window, click the middle of the Blank to select a point. Be careful not
to select the lance line curve.

l. Click Close to return to the D-10 task panel.

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Note that the button next to Mark the area to keep now reads "1 Location(s)".

9. Define the process motions of the operation.

a. Since the process is a typical single-action stretch, the Die, Binder, and Punch can use
the default motion settings.

b. In the Closing column of the table, next to Lance tool, click Drv by to select it and
open the Closing/Lance tool section of the task panel.

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c. Click the drop-down menu next to Driven By and choose Die.

d. In the Drawing column of the table, in the Lance tool row, click Drv by to select it and
open the Drawing/Lance tool section of the task panel.

e. Click the drop-down menu next to Driven By and choose Die.

f. In the Tool column of the table, click Lance tool to select it and open the Lance tool
section.

g. Next to Cut Position and Dis, to Home, enter 4.

h. Click Update to set the position of the lance tool.

10. Set the force of the Binder.

a. In the table, in the Closing column of the Binder row, click Stationary to select it and
open the Closing/Binder section of the task panel.

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b. Check the box next to Force Control, then enter 190000 in the field.

This is the closing force of the Binder in Newtons (N).

c. Click Update to apply your changes to the operation.

11. Define the result output positions.

a. In the table, in the Closing column of the Die row, click Cls to Binder to select it and
open the Closing/Die section of the task panel.

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b. Check the box next to Output Positions.

The default output positions are fine, so leave them unchanged.

c. Click Update to apply your changes.

d. In the table, in the Drawing column of the Die row, click Travel-> Pos:0 to select it
and open the Drawing/Die section of the task panel.

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e. Check the box next to Output Positions.

f. Click Update to apply your changes.

g. In the table, in the Closing column of the Binder row, click Stationary to select it and
open the Closing/Binder section of the task panel.

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h. Check the box next to Output Positions.

i. Click Update to apply your changes.

j. In the table, in the Drawing column of the Binder row, click Drv. by Die to select it
and open the Drawing/Binder section of the task panel.

k. Check the box next to Output Positions.

l. Click Update to apply your changes.

12. Set the initial position of the tool bodies, and check the motion of each tool body.

a. In the D-10 task panel, click Positioning to open the Positioning task panel.

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b. Next to Die, use the drop-down menu to change Auto to Manual.

c. Set the Die positioning to 150 and click Update.

d. Next to Binder, use the drop-down menu to change Auto to Manual.

e. Set the Binder height to 60 and click Update.

f. Set the Lance tool positioning to 150 and click Update.

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13. Use the States tool to check your work.

a. In the ribbon, click the Iso. button ( ) to rotate the view in the Graphics Window to
show an isometric view of the project.

b. Use the tools in the States section to step through or animate the process.

c. Check the movement of the tool bodies to make sure they are correct.

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You may find it helpful to use other View tools in the ribbon to watch the tool move-
ment from different angles.

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14. Click << to return to the D-10 task panel.

15. Save the project database by clicking the Save Project button ( ) in the main toolbar..

[Link]. Set Up the First Trimming Station (T-20)

In the Operations ribbon, click T-20 to enter the trimming setting interface.

Figure 2.15: Trim/Pierce Task Panel

To define the trim operation:

1. Import the lines needed for trimming.

a. In the ribbon, click Import to open the Import task panel.

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b. The tool body for this Trim operation is a curve, so in the Curve section, click the
Import curve ( ) button to open a file browser.

c. Navigate to the directory that contains the provided OP20 input files.

d. Select the IGES file op20 [Link].

e. Click Open.

f. Verify that "op20 [Link]" is now listed in the Curve section of the Import task
panel.

g. Click Close to return to the T-20 task panel.

2. Define the trim lines.

a. Before continuing, limit the graphics window to show only the Trimming Curve
items.

In the Feature Tree, uncheck everything except for "op20 [Link]" and "Trim1".

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b. In the table, click Trim1 to select it and open the Trim1 section.

c. In the Trim1 section of the task panel click Add to open the Pick Curve task panel.

d. In the Pick Curve task panel, click Window to highlight it, then in the Graphics
Window click the curves to select them.

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e. In the task panel, click Close to complete the definition of the trim line and return
to the T-20 task panel.

f. In the T-20 task panel, next to Mark the area to keep, click None to open the
Pick Single Point task panel and define the reserved area.

g. Before continuing, use the Feature Tree in the Graphics Window to display the Die,
which will help you place the retention control point correctly.

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h. In the Graphics Window, click a spot on the Die that is near the middle, inside the
trim lines. This will select a point on the model, and display its coordinates in the
Pick Single Point task panel.

i. Click Close to complete the pick and return to the T-20 task panel. The point you
picked is displayed as a red dot, and the button in the task panel now reads
"1 Location(s)".

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3. Save the project database by clicking the Save Project button ( ) in the main toolbar..

[Link]. Set Up the Second Trimming Station (T-30)

In the Operations ribbon, click T-30 to enter the trimming setting interface.

1. Import the lines needed for trimming.

a. In the ribbon, click Import to open the Import task panel.

b. The tool body for this Trim operation is a curve, so in the Curve section, click the Import
curve ( ) button to open a file browser.

c. Navigate to the directory that contains the provided OP30 input files.

d. Select the IGES files op30 [Link] and op30 [Link].

e. Click Open.

f. Verify that "op30 [Link]" and "op30 [Link]" are now listed in the Curve section of the
Import task panel and in the Feature Tree of the Graphics Window.

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g. Click Close to return to the T-30 task panel.

2. Define the trim that is being performed.

a. In the Cutting Tools section of the task panel, click the button to add a second
Trim set.

b. In the table, click Trim1 to select it, then in the Options section below the table click
the Cam radio button.

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c. In the Options section, check the check box next to Direction, then change the second
coordinate in the field to -1,0,0 .

d. Click Update to save your changes to the trim.

e. In the table, click Trim2 to select it, then in the Options section below the table click
the Cam radio button.

f. In the Options section, check the check box next to Direction, then change the second
coordinate in the field to 1,0,0 .

g. Click Update to save your changes to the trim.

3. Define the line for Trim1.

a. Before continuing, limit the graphics window to show only the relevant items.

In the Feature Tree, uncheck everything except for "op30 [Link]" and "Trim1".

b. In the table, click Trim1 to select it and open the Trim1 section.

c. In the Trim1 section of the task panel click Add to open the Pick Curve task panel.

d. In the Pick Curve task panel, click Window to highlight it, then in the Graphics Window
click the trimming curve to select it.

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e. In the task panel, click Close to complete the definition of the trim line and return to
the T-30 task panel.

4. Define the line for Trim2.

a. Before continuing, limit the graphics window to show only the relevant items.

In the Feature Tree, uncheck everything except for "op30 [Link]" and "Trim2".

b. In the table, click Trim2 to select it and open the Trim2 section.

c. In the Trim2 section of the task panel click Add to open the Pick Curve task panel.

d. In the Pick Curve task panel, click Window to highlight it, then in the Graphics Window
click the trimming curve to select it.

e. In the task panel, click Close to complete the definition of the trim line and return to
the T-30 task panel.

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5. Define the reserved area.

a. In the T-30 task panel, next to Mark the area to keep, click None to open the Pick
Single Point task panel and define the reserved area.

b. Before continuing, use the Feature Tree in the Graphics Window to display the Die and
both trimming curves, which will help you place the retention control point correctly.

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c. In the Graphics Window, click a spot on the Die that is near the middle, inside the trim
lines. This will select a point on the model, and display its coordinates in the Pick Single
Point task panel.

d. Click Close to complete the pick and return to the T-30 task panel. The point you picked
is displayed as a red dot, and the button in the task panel now reads "1 Location(s)".

6. In the T-30 task panel, check the box next to Springback and enable rebound calculation.

The default Springback settings are acceptable for this tutorial so no further configuration is
needed.

7. Save the project database by clicking the Save Project button ( ) in the main toolbar.

[Link]. Set Up the Flanging Station (F-40)

In the Operations ribbon, click F-40 to enter the flanging setting interface.

Figure 2.16: The Flanging Operation Task Panel

1. Define the tool surface offset.

a. In the F-40 task panel, click the OP Setting ( ) button to open the OP Setting task
panel.

b. Click the Define Offset radio button to select it.

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c. Check the box next to Lower Tool(s) to activate this setting, and enter 1 in the field.

d. Click Apply to update the operation setting.

e. Click Close to return to the F-40 task panel.

2. Import the lines needed for flanging.

a. In the ribbon, click Import to open the Import task panel.

b. The tool body for this flanging operation is a surface, so in the Surface section, click
the Import surface ( ) button to open a file browser.

c. Navigate to the directory that contains the provided OP40 input files.

d. Select the IGES files op40 [Link], op40 lower [Link], op40 [Link], and
op40 [Link].

e. Click Open.

f. Verify that "op40 [Link]", "op40 [Link]", "op40 lower [Link]", and
"op40 [Link]" are now listed in the Surface section of the Import task panel and in
the Feature Tree of the Graphics Window.

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g. Inspect the imported surfaces, checking whether there are missing faces, few faces, or
distortions on the faces.

h. Click Close to return to the F-40 task panel.

3. Add a new tool body to the lower module, and rename tools.

a. In the first column of the settings table, click Post to highlight it.

b. Click the +Tool button to add a new tool below the Post tool.

c. Right-click Tool4 and choose Rename from the drop-down menu.

d. Set the tool name to Lower pad and click OK to return to the F-40 task panel.

e. Rename Flg4 to Die.

f. Rename Post to Punch.

4. Define the flanging pad.

a. Before continuing, use the Feature Tree in the Graphics Window to display only the
"op40 [Link]" tool surface.

b. In the table, click Pad to highlight it, and then in the Pad section of the task panel click
Select to open the Define Pad by Surface task panel.

c. In the task panel, click Window to highlight it, then click-and-drag in the Graphics
Window to select the entire displayed surface.

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d. Click Apply to update the tool setting.

e. Click Close to return to the F-40 task panel.

5. Define the die of the upper module.

a. Before continuing, use the Feature Tree in the Graphics Window to display only the
"op40 [Link]" tool surface.

b. In the table, click Die to highlight it, and then in the Die section of the task panel click
Select to open the Define Die by Surface task panel.

c. This time, use a different method to select the tool surface. In the task panel, click
Window to highlight it, then click Displayed to select the displayed surface.

d. Click Apply to update the tool setting.

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e. Click Close to return to the F-40 task panel.

6. Define the punch.

a. Before continuing, use the Feature Tree in the Graphics Window to display only the
"op40 [Link]" tool surface.

b. In the table, click Punch to highlight it, and then in the Punch section of the task
panel click Select to open the Define Punch by Surface task panel.

c. This time, use a different method to select the tool surface. In the task panel, click By
Part to open the Part List, then check the box next to "op40 [Link]" and click
Close.

d. Click Apply to update the tool setting.

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e. Click Close to return to the F-40 task panel.

7. Define the lower pad of the lower module.

a. Before continuing, use the Feature Tree in the Graphics Window to display only the
"op40 lower [Link]" tool surface.

b. In the table, click Lower pad to highlight it, and then in the Lower pad section of the
task panel click Select to open the Define Lower pad by Surface task panel.

c. Use your favorite method to select the tool surface.

d. Click Apply to update the tool setting.

e. Click Close to return to the F-40 task panel.

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8. Add a motion control phase to the table.

a. Click triangle in the +Tool ( ) button in the settings table to open the menu.

b. Choose +Phase from the menu.

9. Define the motion of the pad.

a. In the table, in the Closing column of the Pad row, click Cls to Punch to highlight it.

b. In the Closing/Pad section of the task panel, use the drop-down menu to change Punch
to Lower pad.

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c. Change Phase3/Pad from Stationary to Travel Until Distance to Home 0 (zero), then
click Update.

10. Define the motion of the die.

a. Leave Closing/Die as Stationary.

b. Change Forming/Die to Closing To Lower pad.

c. Change Phase3/Die from Stationary to Driven By Pad.

11. Define the motion of the lower pad.

a. Change Closing/Lower pad from Fixed on Bed to Stationary.

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The Lower pad row will move up one position in the table, and other settings will
change.

b. Leave Forming/Lower pad as Stationary.

c. Change Phase3/Lower pad from Stationary to Driven By Pad.

12. Set the output position of the operation.

a. At the top of the F-40 task panel, click the Parameters Setting ( ) button to open
the OP Parameter Settings task panel.

b. Check the box next to Output Positions.

c. Click Apply.

This sets the output positions of every tool movement in the operation.

d. Click Close to return to the F-40 task panel.

13. Set the initial position of the tool bodies, and check the motion of each tool body.

a. In the F-40 task panel, click Positioning to open the Positioning task panel.

b. Next to Lower pad, use the drop-down menu to change Auto to Manual.

c. Set the lower pad height to 30 and click Update.

d. Use the tools in the States section to step through or animate the process.

Check the movement of the tool bodies to make sure they are correct, and that there
is no interference.

e. Click << to return to the F-40 task panel.

14. Save the project database by clicking the Save Project button ( ) in the main toolbar.

[Link]. Set Up the Third Trimming Station (T-50)

In the Operations ribbon, click T-50 to enter the trimming setting interface.

1. Import the lines needed for trimming.

a. In the ribbon, click Import to open the Import task panel.

b. The tool body for this Trim operation is a curve, so in the Curve section, click the Import
curve ( ) button to open a file browser.

c. Navigate to the directory that contains the provided OP50 input files.

d. Select the IGES files op50 [Link].

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e. Click Open.

f. Verify that "op50 [Link]" is now listed in the Curve section of the Import task panel and
in the Feature Tree of the Graphics Window.

g. Click Close to return to the T-50 task panel.

2. Define the line for Trim1.

a. Before continuing, limit the graphics window to show only the relevant items.

In the Feature Tree, uncheck everything except for "op50 [Link]" and "Trim1".

b. In the table, click Trim1 to select it and open the Trim1 section.

c. In the Trim1 section of the task panel click Add to open the Pick Curve task panel.

d. In the Pick Curve task panel, click Window to highlight it, then in the Graphics Window
click the trimming curve to select it.

e. In the task panel, click Close to complete the definition of the trim line and return to
the T-50 task panel.

3. Define the reserved area.

a. In the T-50 task panel, next to Mark the area to keep, click None to open the Pick
Single Point task panel and define the reserved area.

b. Before continuing, use the Feature Tree in the Graphics Window to display the Pad and
trimming curve, which will help you place the retention control point correctly.

c. In the Graphics Window, click a spot on the Pad that is outside the trim line. This will
select a point on the model, and display its coordinates in the Pick Single Point task
panel.

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d. Click Close to complete the pick and return to the T-50 task panel. The point you picked
is displayed as a red dot, and the button in the task panel now reads "1 Location(s)".

4. In the T-30 task panel, check the box next to Springback and enable rebound calculation.

The default Springback settings are acceptable for this tutorial so no further configuration is
needed.

5. Save the project database by clicking the Save Project button ( ) in the main toolbar.

[Link]. Verify the Operations Settings

Once all Operations are defined, use the Verify OP command to check for project errors.

In the T-50 task panel, click the Verify OP ( ) button. This checks all operations of the process
for parameter leakage.

If any operations are missing parameters, a red line will appear in the Operations tab and in the
ribbon under the operation that is not complete.

If no operations have any major problems, a green line will appear in the Operations tab.

This does not mean that all parameters of all operations are correct, just that there are no major
parameter errors that block you from continuing.

2.2.4. Run the Project

Click Runner in the Operations ribbon and to access the Runner task panel. Use this panel to set
simulation parameters and start the simulation.

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Figure 2.17: Runner, Ready

Click any step in the table to highlight it and change settings for that operation. You may modify the
number of CPU cores used for calculation. The default is 4 cores. If you have a high-performance
computer with many CPU cores, and an HPC license for the software, you may increase the number
of cores accordingly. You may also increase the memory limit. To return a calculation's settings to
the default values, click Default.

If you have changed the settings for one step, you can click the triangle next to Default to open the
drop-down menu and choose Current to All to assign those values to all steps in the process. To
return all steps to the default values, click the triangle next to Default to open the drop-down menu
and choose Default to All.

Once set, click Start to start the calculation.

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Figure 2.18: Runner, Completed

The Status bars for each step in the process update until they reach 100%. You may pause the simu-
lation at any point by clicking Stop. To continue the analysis, click Start again. The simulation restarts
from the interrupted operation, not from the beginning of the process, so it is not necessary to use
Stop carefully.

While the simulation is running, you can save a copy of the current project using the Save a Copy
command in the System Tools menu. The copy will open in a new tab. You can then make modific-
ations to the new project while waiting for results. The file name of the copy is the original file name
incremented with a number.

There is no need to wait for all simulation operations to complete before proceeding to analysis. As
soon as the first output point occurs, those results are available for postprocessing. As more operations
complete, more results will be available. This enables you to evaluate the forming process operation
by operation, while the simulation progresses, and stop the simulation if any operation produces
unsatisfactory results.

2.3. Postprocessing Analysis

Click Analysis tab in the main toolbar to access the postprocessing tools and analyze the forming
process you defined.
2.3.1. View a Simulation Summary
2.3.2. View Deformation Results
2.3.3. View Edge Draw-In
2.3.4. Evaluate Springback

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2.3.5. View and Export a Tonnage Prediction Plot

2.3.6. Export a Mesh of the Final State

2.3.1. View a Simulation Summary

Choose Summary from the Additonal Tools drop-down menu to display the Summary task panel
and view a text report of simulation details and statistics about the simulation process.

Figure 2.19: Simulation Summary

For more information about the summary, see Viewing a Simulation Summary in the Forming User's
Guide.

When you are finished with the Summary, click Close.

2.3.2. View Deformation Results

Use the tools on the Deformation task panel to view the simulated results of the Forming process.
Click any state in the list to view the workpiece shape at that point in the forming process. The first

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state shows the Blank at the start of the forming process. The final state shows the completely formed
part. You may find it helpful to check and uncheck Tools in the Feature Tree to view how tools interact
with the Blank during the forming process.

Figure 2.20: Deformation, State # 1

Figure 2.21: Deformation, State #64

To view the simulated forming process as an animation:

1. If it is not already selected, choose All Ops from the drop-down menu above the list.

2. Check the box next to All to select all states in the list.

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3. Click Play ( ) to start the animation on a loop.

The first time through the animation, the steps change as calculated date is interpreted.
Subsequent passes through the animation are faster. Use the left-hand slider to increase or
decrease the speed of the animation.

4. Click Pause ( ) at some point to pause the animation.

5. Click the forward frame and back frame buttons to move through the process step by step,
viewing individual states.

6. Click Stop ( ) to end the animation.

2.3.3. View Edge Draw-In

The draw-in function displays a vector plot of blank draw-in over the binder surface. Click Draw-In
in the ribbon to display the Edge Draw-In task panel and view a plot of analysis data that displays
vectors highlighting the draw-in of edges during the forming process.

Figure 2.22: In-Flow Draw-In

Use the animation controls to view draw-in vectors during any state.

For more information, see Viewing Edge Draw-In.

When you are finished with the edge draw-in plot, click Close.

2.3.4. Evaluate Springback

The springback evaluation diagram enables you to view calculated springback data, and measure
springback data by comparing the simulated part shape to a reference shape. Either the upper or
lower surface of the simulated part can be compared. Tool meshes are often used as a reference

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shape. Choose Springback from the ribbon to display the Springback Evaluation task panel and
view a diagram of the springback in the part.

Figure 2.23: Springback Evaluation

To compare the final part shape to the original die surface:

1. From the first drop-down menu in the Part Shape to be Evaluated section, choose [Link].

2. Click time #2 in the list to highlight it.

3. Check the Part Shape Offset To check box and choose Upper Side from the drop-down
menu to offset the simulated part shape to match the upper side of the actual part before
performing the comparison.

4. In the ribbon, click Import to open the Import task panel, and import "op10 [Link]" as a
surface.

5. In the Reference Shape section, click the … button and pick the imported surface from the
Pick Reference Part task panel.

For more information, see Springback Task Panel

When you are finished with the Springback Evaluation plot, click Close.

2.3.5. View and Export a Tonnage Prediction Plot

The tonnage prediction plot displays plot tonnage predictions versus displacement for selected oper-
ations. This will enable you to determine if the tonnage required by the operation exceeds the cap-
abilties of your forming equipment.

1. In the Analysis ribbon, click Tonnage to display the Tonnage task panel.

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2. In the Tonnage task panel, click D-10 to select it.

3. Click Plot to open a Tonnage Predicition plot window for operation D-10.

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Box Tutorial

The Tonnage Prediction window displays the force of each phase of the operation (in Newtons)
over Distance to Home (in millimeters).

4. In the top table, click a phase of the operation to display the numerical Values for that phase's
curve.

5. Beneath the Values table, view the minimum and maximum force applied to the workpiece during
that phase.

6. In the plot, right-click to open the context menu, and choose Export….

7. Use the Export as image file dialog box to select a location, name, and file type for the exported
image.

8. Click Save to export the plot to an image file.

9. When you are finished viewing the tonnage prediction plot, use the Close button in the window's
title bar to return to the main application window.

2.3.6. Export a Mesh of the Final State

After running the simulation, you may wish to export the final formed sheet to a mesh file for further
processing in another piece of software.

1. Click the last frame button to view the final part in the Graphics Window.

2. Click Export in the ribbon to open a Save file dialog box.

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 Postprocessing Analysis

3. Navigate to the top level of the project directory, "Box Forming Process".

4. Choose a file type for the export. Available file types are:
• LS-Dyna Dynain File (*.dynain)
• IGES Data File (*.igs)
• Blank Shape (*.stl)

5. Click Save.

Release 2025 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 71
 Release 2025 R2 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
72 of ANSYS, Inc. and its subsidiaries and affiliates.