Tube Rotary Bending

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Roller Hemming
DYNAFORM 5.8 Training Tutorial
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Tutorial
This tutorial illustrates how to setup roller
hemming simulation
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1. Open Database

• Start eta/DYNAFORM
• For PC users double click the icon on
  desktop to start eta/DYNAFORM
• For Linux and UNIX users enter df58 in the
  command line and press Enter button to start
  eta/DYNAFORM.
• Click File menu and select Open submenu (See
  Figure 1).
• Select the hemming.df and click Open to open the
  DF file. (See Figure 2).

Figure 1
Figure 2
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1. Open Database

Figure 3
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1. Enter Roller Hemming

1. Click AutoSetup menu and select Roller Hemming
   submenu (See Figure 4).
2. Default title is untitled, change it to Roller
   Hemming (See Figure 5).

Figure 4
Figure 5
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1. Define Outer Panel

1. Click Outer panel page.
2. Click Define geometry to enter Blank generator
   (See Figure 6).
3. Click Add part in blank generator (See Figure 7).
4. Select the part OUTER, FLANGE and click OK to
   exit (See Figure 8).
5. Click Exit to exit Blank generator (See Figure 9).

Figure 6
Figure 7
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1. Define Outer Panel

1. Click BLANKMAT to define Outer panel material
   (See Figure 10).
2. Click Material Library to select the material
   (See Figure 11).
3. Select the material BH180 (See Figure 12).
4. Click OK button to exit the Material dialog box
   (See Figure 13).

Figure 10
Figure 9
Figure 8
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1. Define Outer Panel

Figure 11
Figure 12
Figure 13
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1. Define Outer Panel

1. Input OUTER Thickness 0.8 (See Figure 14)
2. Use the same material parameter for FLANGE.

Figure 14
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1. Define Inner Panel

1. Click Inner panel page.
2. Click Define geometry to Enter Preparation.
3. Click Define tool icon in Preparation (See Figure
   16).
4. Click Add part in Define geometry dialog box (See
   Figure 17).
5. Select the part INNER and click OK to exit (See
   Figure 18).
6. Click Exit to exit define geometry (See Figure
   19).
7. Click Exit to exit Preparation.

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1. Define Inner Panel

Figure 17
Figure 16
Figure 15
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1. Define Inner Panel

1. Click BLANKMAT to define inner panel material
   (See Figure 20).
2. Click Material Library to select the material
   (See Figure 21).
3. Select the material BH180 (See Figure 22).
4. Click OK button to exit the Material dialog box
   (See Figure23).

Figure 19
Figure 20
Figure 18
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1. Define Inner Panel

Figure 20
Figure 21
Figure 22
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1. Define Inner Panel

1. Input INNER thickness 0.8 (See Figure 24).

Figure 24
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1. Define Roller

1. Click Tools page.
2. Select Roller as current tool.
3. Click Define geometry to enter Preparation (See
   Figure 25).
4. Click Define tool icon in Preparation.
5. Click Add part in Define geometry dialog box (See
   Figure 26).
6. Select the part PREROLL and click OK to exit (See
   Figure 27).
7. Click Exit to exit Define geometry dialog box
   (See Figure 28).

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1. Define Roller

Figure 25
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1. Define Roller

Figure 26
Figure 27
Figure 28
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1. Define Hem Bed

1. Click Hem Bed as current tool in Preparation.
2. Click Define tool icon in Preparation (See Figure
   29).
3. Click Add part in Define geometry dialog box (See
   Figure 30).
4. Select the part HEMBED and click OK to exit (See
   Figure 31).
5. Click Exit to exit Define geometry dialog box
   (See Figure 32).
6. Click Exit to back setup.

Figure 29
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1. Define Hem Bed

Figure 31
Figure 30
Figure 32
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1. Define Trajectory

1. Click Process page .
2. Click Edit to define roller trajectory (See
   Figure 33).

Figure 33
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1. Define Trajectory

1. Click Create path in Define Roller dialog box
   (See Figure 34).
2. Click Element in Create Path dialog box (See
   Figure 35).
3. Select all FLANGE elements in select elements
   dialog box and click OK to exit (See Figure 36).

Figure 34
Figure 35
Figure 36
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1. Define Trajectory

1. Click Start Node in Create Path dialog box (See
   Figure 37).
2. Select a node as start node in graphic displayed
   area (See Figure 38).
3. Click OK to exit (See Figure 39).

Figure 37
Figure 38
Figure 39
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1. Define Trajectory

1. Click End Node in Create Path dialog box (See
   Figure 40).
2. Select a node as end node in graphic displayed
   area (See Figure 41).
3. Click OK to exit (See Figure 42).

Figure 40
Figure 41
Figure 42
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1. Define Trajectory

1. Check the direction of roller trajectory (See
   Figure 43).
2. Toggle on Create Line to create the trajectory
   as a line (See Figure 44).
3. Click Apply to define the trajectory.

Figure 43
Figure 44
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1. Define Trajectory

1. Check the Rotate a (taper angle) and Rotate b
   (lead angle).
2. Check the velocity of roller.
3. Click OK to exit Roller Define dialog box.

Note Use default value in this case.
Figure 45
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1. Define Trajectory

1. Toggle on Springback seamless if user want to
   run a springback after hemming simulation (See
   Figure 46).

Figure 46
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1. Constraint

1. Click Outer panel tab.
2. Click Edit to define SPCs (See Figure 47).
3. Select All and click New to select nodes (See
   Figure 48).
4. Select Near Line type.
5. Select the line (create line when the definition
   of roller trajectory) in graphic display area and
   click OK in Tolerance to Line dialog box (See
   Figure 49).
6. Click OK to exit Select Node dialog box (See
   Figure 50).
7. Click OK to exit SPCs dialog box (See Figure 51).

Figure 47
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1. Constraint

Figure 49
Figure 48
Figure 51
Figure 50
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1. Constraint

1. Click Inner panel tab.
2. Click Edit to define SPCs (See Figure 52).
3. Click New to select nodes (See Figure 53).
4. Select some nodes in graphic display area (See
   Figure 54).
5. Click OK to exit Select Node dialog box (See
   Figure 55).
6. Click OK to exit SPCs dialog box (See Figure 56).

Figure 52
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1. Constraint

Figure 54
Figure 53
Figure 56
Figure 55
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1. Define Control

1. Click Control tab.
2. User can click button, the program will
   automatically calculate the time step size
   according to material parameters and element size
   of outer panel and inner panel.
3. Set the time step as -1.2e-007 (See Figure 57).
4. User can toggle on Refining meshes to define
   refinement frequency and refinement levels.

Figure 57
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1. Animation

1. Click Preview menu and Animation submenu (See
   Figure 58).
2. Click Play Button to show the animation, and user
   can also select the Individual Frames option to
   display the incremental roller movement (See
   Figure 59).

Figure 58
Figure 59
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1. Input Deck

1. Click Job ? LS-DYNA Input Deck button (Figure
   60).
2. The program popup a Save As dialog box, and click
   Save to output input deck (Figure 61).
3. The input deck can be submitted to Job Submitter
   to run.

Figure 60
Figure 61