DYNAFORM 7.2.2 is the latest build (e.g., Build 2024.12.03) of ETA’s sheet metal forming simulation software based on the LS-DYNA solver, tailored for die design and evaluation. It covers the entire die system process, from blank engineering to structural analysis. Compared to version 7.1, it significantly improves speed, precision, and efficiency, introducing innovations like hot forming and drop testing. Ideal for automotive, aerospace, and manufacturing industries, this version enhances the Sigform solver with adaptive meshing, multi-stage stamping, gravity loading, springback compensation, and press tonnage prediction, helping users reduce production time, minimize errors, and boost profitability.
Key Modules and Features
- Blank Size Engineering (BSE): Estimates blank size with support for 1-up, 2-up, mirrored, and multiple blank nesting configurations to maximize material utilization and minimize scrap. Automatically generates reports including overall blank size, nesting layout, pitch, coil width, annual volume requirements, and total piece cost. New optimization algorithms enhance nesting efficiency.
- Die Face Design (DFD): Bridges estimation and tool-building processes with surface edit tools for generating binders and addendums. New features like Auto CAM, Trim Segment, and Flange tools facilitate multi-stage die face design operations, such as trimming and flange modifications, for greater flexibility and intuitiveness.
- Formability Simulation (FS): Produces Forming Limit Diagrams (FLD) to predict major strains, cracks, wrinkles, thinning, and surface defects. New additions include Clamping Springback (measuring springback with pads, pilot pins, and clamps for sequential closing) and Hot Forming (user-friendly interface simulating high-strength steel processes from gravity and forming to cooling and hardening).
- Die Evaluation (D-Eval): Analyzes CAD-based tooling with early CAD evaluation, die surface modification, trimline checks, and scrap size verification. Integrates INCSolver for fast, reliable formability results.
- Die Structural Integrity (DSI): Dynamically analyzes die structures, providing insights into mechanical performance, load-bearing capacity, and stress-prone areas to identify potential failures.
- Sheet Drop Test: Industry-first module simulating part deformations during production drops and transfers to ensure dimensional accuracy (e.g., for automotive assemblies). Identifies gravity-induced deviations and surface defects to prevent costly errors.
- Tube Bending & Forming (TBF): Simulates CNC bending and hydroforming for tubular products, supporting multi-stage processes (bending, preforming, hydroforming, trimming, annealing). Predicts wrinkles, cracks, springback, and hydroforming feasibility; enhances simulations for simultaneous tube feeding, rotation, and bending; supports bending table editing and seamless data exchange with bending machines.
- Auto-Tool Creation: Robust automated creation of upper and lower tools based on product geometry.
- FEA Preparation: Handles motion definition, mesh editing, and more within DYNAFORM, reducing reliance on external CAD software.
- Scrap Removal (DSA – Die System Analysis): Simulates scrap flow and sheet metal transfer to address shutdowns from scrap removal failures.
Core Advantages
- Enhanced Sigform Solver: Designed specifically for sheet metal forming, it supports parallel computing for rapid, accurate multi-stage simulations that are fast, precise, and cost-effective.
- Integrated Workflow: No data conversion needed; all operations in a single interface. Supports IGES, VDA, DXF CAD interfaces, and NASTRAN, IDEAS CAE interfaces.
- Applications: Automotive (body panels), aerospace (structural components), appliances (kitchenware, AC housings), predicting springback, stresses, and surface quality for complete die system solutions.
