AutoForm Hydro

iletisim: omarer25@hotmail.
com
ALGHAFORM PAYLASIMIDIR
iletisim: omarer25@hotmail.com
www.forum.alghaform.com
6 AutoFormHydro
AutoFormHydro is an AutoForm Software package for simulation

of tube hydroforming processes processes that use internal fluid
pressure, acting in conjunction with the movement of axial and
radial tools, to form and shape tubular blanks.
In simulations using AutoFormHydro, load application through
the fluid medium may be specified by pressure, volume and
heightcontrol. In the first variant, pressurecontrol, evolution of
pressure during the forming process is specified by the user, and
the resulting volumetric change is computed during the analysis. In
the second case, volumecontrol, the desired change of volume is
specified and the required pressure is calculated. The third variant,
heightcontrol, allows the user to define the approximate radial
expansion of the tube during the deformation process. The resulting
volumetric change and the required pressure are then calculated
during the analysis.
Volume and heightcontrol may be used in the early stages of process design, when pressure history and optimal tool kinematics are
as yet unknown.
Pressurecontrol should be used if the user already has a reasonable
idea of its evolution during the deformation process (experience,
similar processes, similar parts, etc.).
The following tube deformation process components may be simulated using AutoFormHydro:
Prebending
Annealing
Preforming (closing of tools without fluid medium)
Hydroforming (Forming with fluid medium)
In the current version, version 3.1, prebending is simulated in a single time step. This is a stable and efficient way to simulate prebending whereby changes in thickness and material hardening arising
from prebending may be computed. However, change in cross sectional shape during prebending cannot be established using this
singlestep approach.
If shape of the tube cross section is important to simulate accurately

subsequent forming stages (for example, if the prebent tube does
not have the right shape in its cross section, it may not be possible to
position it in the hydroforming tools), prebending may be simulated using the preforming process step. CAD models of the prebending tools components of the complete tool that define the bent
shape of the tube are required in this case. The current version
does not allow the simulation of rotary prebending operations.
One of the most important features of AutoFormHydro is its user
friendliness and the ease with which simulations may be set up, run
and evaluated. As with all other AutoForm Software packages, preprocessing and data input are tailored to the logical needs of the different simulation types. Such a userfriendly design of the software
allows even the casual/occasional user to set up and run simulations
and to thus carry out feasibility assessments reliably, easily and
quickly.
This chapter illustrates the application as well as features of the
AutoFormHydro software package based on a series of tutorial
lessons. Each lesson introduces new software features and highlights some of the wide variety of application possibilities. It is recommended that the user work through the lessons in the order
listed here as this order represents a progression in the complexity
of usage and features, and since each lesson assumes familiarity
with features illustrated in the previous ones.
In particular, Lesson 1 gives a very detailed description of the steps
involved in the preparation and set up of a typical AutoForm
Hydro simulation, and is ideal for introducing the new user to the
software. Special applications are described in detail in subsequent
lessons where some familiarity with the software is assumed.
Contents of the Workshop AutoFormHydro

Lesson 1
Set up of a Simulation with Linear Pressure History.

History. . . . . . . . . . 4
Lesson 2
Specification of Axial Tools and their Movement . . . . . . . . . . 48
Lesson 3
Creating a new simulation file

Importing CADgeometry
Specifying upper and lowertools
Defining initial tube geometry
Setting up process steps
Starting the simulation
Post processing results of the simulation
Opening an existing simulation file

Inserting new tools (axial tools)
Modifying the process step hydroforming
Starting the simulation
Post processing results of the simulation
Definition of Timedependent Pressure

and ToolControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Specifying an annealing process step
Defining fluid pressure versus time
Defining tool movement as a function of time
Lesson 4
Simulation of Hydroforming using a Counterpunch . . . . . . . . 71
Defining geometry of a counterpunch

Specifying working direction for counterpunch
Specifying fluid pressure versus time
Specifying movements (distance versus time) of counterpunch and axial tools
Lesson 1: Set up of a Simulation with Linear Pressure History
6. 1 Lesson 1: Set up of a Simulation with Linear Pressure

History
As a first step in setting up, running and evaluating an AutoFormHydro simulation, it is
necessary to open a new simulation file and to name it appropriately. This simulation
file provides the right context, within the AutoFormUser Interface, for importing
required data CAD geometries, lines, material data, etc. and for setting up a simulation as desired. In the present lesson, tool geometries will be defined on the basis of
imported CAD geometries, the initial tube will be defined from its centerline and diameter, and a process sequence (comprising prebending, closing and hydroforming
steps) will be established, with linear pressure evolution during hydroforming. Following
these steps, the simulation may be started up, and simulation results may be evaluated/post processed.
Fig. 1.1
Part geometry lesson 1
Import of a CADgeometry
Starting up the AutoForm UserInterface

The AutoFormUser Interface may be started up either by double
clicking on the predefined AutoForm icon on the users desktop, or
by using the command xaf at the prompt of an open UNIX shell
window. The User Interface displays the AutoForm Logo upon start
up.

Fig. 1.2
AutoFormUser Interface
Creating a new simulation file
User interface
File > New ... > New file > File name: hy_lesson_01 > OK
Fig. 1.3
Dialog box: New file

File name: Enter name of *.sim file (without extension)
Units: Select units to be used for inputs. Length units
should be the same as used in the CAD system.

Geometric error tolerance: Enter value of acceptable
chordal deviation error, to be used for meshing (see
below). Default value is adapted to the length units
selected under Units. Typical values are between 0.05 and
0.1 mm.
Note:
Note An input field, in any of the AutoForm input utilities, that is
highlighted in red indicates that user input is mandatory in the
respective field. Upon appropriate user input, these fields turn
white. Input fields containing software default parameter values are
also displayed in white; the user may modify the parameter values
in these fields as required.
Importing CADgeometry
Clicking on the OK button after completing inputs in the New file
dialog box starts up the Geometry generator a utility for importing and preprocessing surface geometry.
Fig. 1.4
Geometry generator: Prepare page

The surfaces representing tool geometry (CADmodel of the tool)
need to be imported and used to define tools for the simulation.
These surfaces may be imported either from an IGES or from a
VDAFSformat file. During the process of importing such files, the
AutoFormAutomesher automatically converts (in the background)
the analytical surface descriptions into a mesh, and displays the
meshed geometry in the main display. The meshed geometry may
be examined visually for problems such as untrimmed or overlapping surfaces, and/or gaps between surfaces. If such problems do
exist, they need to be fixed in the CAD system, and the corrected
tool geometry needs to be reexported (in IGES or VDAFSformat), and reimported into the AutoFormUser Interface.
Reading in and meshing the CADmodel
Geometry generator
File > Import ...

The dialog box Import geometry is displayed. Here the format of
the geometry file has to be selected. For Lesson 1 the CAD data of
the tools is available in IGESformat.
Fig. 1.5
Dialog: Import geometry

Import geometry > Format: IGES > OK
Upon clicking OK, a file browser dialog box (Select a file) opens up
from where the user selects the file to be imported.

Fig. 1.6
Dialog: Select a file

Select a file > Files: hy_lesson_01_tools.igs > OK
Upon clicking the button OK a new dialog box the AutoForm
Automesher interface opens up.
Fig. 1.7
Dialog box: AutoFormAutomesher interface

The quality of mesh created over the tool surfaces in the IGESformat file is controlled by the AutoFormAutomesher parameters
listed in the interface.
Parameters:
Error tolerance: Determines the chordal deviation error for

meshing. This value is taken from the New file input interface (default: 0.1; see Fig. 1.3), but may be modified here. If
the imported surface geometry has small radii (2 mm or
less), this value should be reduced to 0.05.
Max side length: Maximum element side length in flat
areas.
Faces:
Treat only: Only faces with specified numbers will be

meshed.
Exclude: Faces with specified numbers will not be meshed.
Layers:
Treat only: Only layers with specified numbers will be

meshed.
Exclude: Layers with specified numbers will not be
meshed.
Program: afmesh_3.1 > OK
Clicking the OK button starts up automatic mesh generation using
the AutoFormAutomesher (afmesh_3.1). Mesh generation typically requires a few seconds. The progress of the mesh generation
can be tracked in the output area of the AutoFormAutomesher
interface.
Following mesh generation, the meshed geometry is displayed in
the main display.
Note:
Note Please refer to Lesson 2 and Lesson 4 of the workshop AutoFormUser Interface for detailed instructions on controlling the display of geometry in the main display of the AutoFormUser
Interface.
No further inputs or actions are required in the Geometry generator, and it may therefore be closed. All further inputs may be
defined entirely from within the AutoFormInput generator.
Geometry generator
File > Dismiss
Working with the Input generator
Start of the input generator
User interface
Model > Input generator ...

Upon making the above menu selection, a dialog box appears
wherein the type of simulation set up (Incremental, OneStep or
Hydro) needs to be selected and the sheet/tube thickness needs to
be specified.
Fig. 1.8
Dialog box: Simulation type

Selection of the type of simulation
Simulation type > Simulation type: Hydro
Upon selecting Hydro the dialog changes to the form:
Fig. 1.9
Window: Simulation type Hydro

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Choice of tube wall thickness
Simulation type > Tube thickness: 1.2 > OK
The Input generator utility (Fig 1.10) opens up. The Input generator
is organized into 6 pages with their respective tabs titled as follows:
Title, Tools, Tube, Lube, Process and Control. These titles indicate
the type of input data to be specified in each page. Further, tab titles
highlighted in red indicate that one or more user inputs are
required in the corresponding page. Although explicit user input
may not be required in pages titled in black, the user is advised to
check the correctness of the default input values in these pages
before starting a simulation: AutoForm only checks for the presence
of parameters in these pages, but NOT for their correctness/appropriateness for the simulation being set up. It is recommended that
the user traverse the pages from left to right completing the
required definitions/inputs under each page.
Fig. 1.10
Input generator: Title page

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Input generator: Title
Under Title, the user may include a brief description of the present
simulation/product. The content of this box is displayed in the
lower left corner of the main window and also appears as an annotation on a postscript printout/file output.
Title
Title: hy_lesson_01 (training, date)

Note:
Note While a brief title consisting of the simulation file name,
username and current date is automatically created, this may be
edited and modified by the user.
In addition to the Title field, the user may write in a description of
the current level of development, material, etc. in the field titled
Comments (Fig. 1.10).
Input generator: Tools
Two types of tools may be specified for an AutoFormHydro simulation: Lateral and Axial.
Lateral: Lateral tools work/move laterally to the tube.
For example upper and lowerdie, all preforming tools,
sliders, counterpressure punch (radial punch) etc.
Axial: Axial tools work/move axially to the tube. Axial
punches/counterpunches that are used to facilitate targeted material flow in the forming zone may be defined
using this option. Only two axial tools can be defined.
Axial start at the beginning of the tube and Axial end at
the end of the tube.
A page needs to be created under the Tools page for each tool in the
simulation. One such page, for the lateral tool (die), is already
defined (Fig. 1.11). Tool pages for additional tools need to be created by the user. In Lesson 1 two lateral tools (upper and lower
die) have to be defined. Definition and usage of axial tools will be
described in Lesson 2.
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Fig. 1.11
Input generator: Tools page

First the predefined tool die needs to be renamed as upper_die.
This is accomplished very easily by clicking the mouse pointer in
the input field Name (Fig. 1.11) and typing in the new name.
Tools
die > Tool name > Name: upper_die > Enter

The subpage die is thus renamed as upper_die.
Tool geometry must now be defined. This may be carried out by
using one of two options: Reference ... and Read f. file ... (Fig 1.11).
Reference: Based on the tool geometry entities already
imported (Geometry generator). Currently active meshed
faces of the selected imported entity may be assigned to the
tool.
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Read f. file: By reading in tool geometry previously saved
to file in AutoFormformat (e.g. tool data from earlier simulations).
Tools
upper_die > Geometry: Reference ...

A new dialog box appears (Fig. 1.12) wherein faces may be selected
that may then be defined as the tool geometry. The following are
the available options for selecting faces:
Fig. 1.12
Window: Reference tool geometry

Current geometry: The valid geometry is displayed and all
further actions refer to this geometry. If more than one
geometry is available in the geometry generator the appropriate one may be selected here.
Pick faces: In the current version of AutoFormHydro,
Pick faces is the only available method for identifying
geometry (tool surfaces) for subsequent definition.
Activate/Deactivate: Faces may be picked or highlighted
using the rightmouse button (or Shift right mouse button). Once picked, these faces may be activated or deactivated using the Activate/Deactivate button. If a picked
face is already active, it may only deactivated. Conversely,
an active face may only be deactivated. Also, it is only possible either to activate or to deactivate a face at a time: it is
not possible to activate a few of the picked faces and to
simultaneously deactivate others.
Activate all: The button Activate all activates all faces. This
option is used to activate the whole model.
Toggle active: The button Toggle active inverts the activation status of the objects in the geometry file: it activates
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the deactivated objects and deactivates those that are activated.
The faces of the tool upper_die are selected as follows:
To select a face that will be part of the tool to be defined,
click on the desired face with the right mouse button
Note:
Note Several faces can be selected using the Shift right mouse
button combination. This key combination may also be used to
create a rectangular rubber band which may be used to enclose
a set of faces to be selected. Two selection possibilities are available:
Only those faces that lie entirely within the rubber band may be
selected, or those faces that are entirely within the rubber band
and those that intersect the rubber band may be selected. It is
possible to toggle between these options as follows: File > Preferences > Select crossing (on or off).
Select the faces which represent the tool to be defined, and activate
them, as shown in Fig. 1.13.
Fig. 1.13
Necessary faces for the tool upper_die

Complete the definition of tool geometry, after picking the appropriate faces, by clicking on OK in the Reference tool geometry dialog box.
Reference tool geometry > Activate > OK
15

No further inputs are required in this subpage of the Tools page.
However a short description of Position and Offset is given here:
Position: Positioning is used to move the tools into correct
position prior to start of the simulation. The input fields
correspond to the x, y and zcoordinate.
Offset: An input for the offset means that from the new
tool an offset is created with the value in this field. Usually
it is not necessary to specify any offset for hydroforming.
In the field Working direction the working direction for each tool is
defined:
dx dy dz: A vector in x, y and zdirection determines the
working direction for the tool.
Move: Movement of the tools in or opposite to working
direction is defined here.
Tools
upper_die > Working direction > dx dy dz: 0, 0, 1 > Move: -10

Note:
Note The input for Move must be 10 because the tool is moved
against the working direction.
It is also possible to define the working direction by a start/end point
or by a default curve/line.
Tool stiffness is specified in the Stiffness input field. A stiffness
value of approximately 50 is appropriate and should not be
changed. When complete, the upper_die tool input page appears as
shown in Fig. 1.14.
16

Fig. 1.14
Inputs for the tool upper_die in the page Tools

It is necessary to define another tool (lower_die) for the simulation.
To do this, a new subpage has to be created under the Tools page.
Tools
Fig. 1.15
Add tool ...

The Add tool (Fig. 1.15) dialog box opens up.
Dialog box: Add tool

17

Type of tool: The type of the tool (Lateral or Axial, see
above) is defined here.
Default tool settings: Input values, except geometry, of an
earlier defined tool can be taken over (Use settings of
tool:), or the standard settings (Use default settings) can
be selected.
Note:
Axial start or Axial end
end) only standard settings
Note For axial tools (Axial
are available.
Selection of type and settings for the new tool
Tools
Add tool > Type of tool > Lateral >

Use settings of tool: upper_die > Add tool
A new Tools page opens up, with the settings carried over from the
tool page upper_die. For this new tool the name, the geometry and
the working direction must be defined. The procedure to do so is
same as described above.
Settings for the new tool
Tools
tool2 > Name: lower_die > Enter

Geometry > Reference ...
Select faces, from the geometry displayed in the main display, by
using the Shiftright mouse button combination (Fig. 1.16), and
activate the selected ones using the Activate button in the dialog
box Reference tool geometry.
Tools
lower_die > Working direction > dx dy dz: 0, 0, 1

Note:
-10)
Note Setting for Move (-10
-10 was taken over from tool upper_die
automatically.
18

Fig. 1.16
Necessary faces for the tool lower_die

After the inputs for the tool lower_die are completed, the subpage
for this tool should appear as shown in Fig. 1.17.
19

Fig. 1.17
Inputs for the tool lower_die in the page Tools

All specifications on the page Tools are thus complete for Lesson 1.
Input generator: Tube
All details relating to the tubular blank material are specified on
this page (Fig. 1.18).
Note:
Note The designation tube includes all semifinished material with
any cross section drawn along a defined axis.
20

Fig. 1.18
Input generator: Tube page

Three dimensional geometry of the tube axis needs to be specified
first.
If a prebent tube is used during hydroforming, the axis of this pre
bent tube needs to be defined here. This specification is essential
even if prebending of the tube is to be simulated using Prebending
as the first process step.
Note:
Note The prebent tube axis must be present as a curve. Bend
information such as axis and radius of bend may not be used here.
There are different ways to define the tube axis:
Input: Contour of tube axis is created using the Curve editor.
Import: The tube axis is specified directly by import from a
CAD file.
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Copy from: The tube axis is specified as a copy of an existing curve. This curve can be selected from curves listed in
the Curve manager. These curves may have been imported
into the Curve manager from a CADfile, or they may have
been already generated in AutoForm.
Note:
Note After definition of the tube axis the button labeled Input
changes to read Edit.
Edit Now tube axis can be edited using the Curve
editor.
To specify the tube axis an existing curve from a CAD file is
selected.
Import of a tube axis
Tube
Axis > Import ...

The dialog box Import line(s) (Fig. 1.19) appears. Here the format of
the file to be imported has to be selected. For Lesson 1, the CAD
data of the tube axis has been saved in IGESformat
Fig. 1.19
Dialog box: Import line(s)

Import line(s) > Format: IGES > OK
The oftenencountered dialog box Select a file opens up, and
the IGESfile for the tube axis can be selected.
Select a file > Files: > hy_lesson_01_axis.igs > OK
Upon clicking the button OK the AutoFormAutomesher interface
appears. No further inputs have to be specified, and the mesher
afmesh_3.1 is started by clicking OK.
22

After completion of meshing the dialog box Select curve (Fig. 1.20)
appears. Here all meshed curves are listed, and the appropriate one
may be selected for the definition of the tube axis.
Fig. 1.20
Dialog: Select curve

Select curve > Curve 1 > OK
Note:
Note It is also possible to select one or more curves in the main display with the right mouse button.
Tube cross section needs to be specified next. Similar to the definition of tube axis, there are several input modes to specify tube cross
section.
Additionally circular cross section may be defined using the button
Circle. Here the outer diameter may be specified. (Fig. 1.21).
Fig. 1.21
Dialog: Cross section - Circle

Tube
Cross section > Circle ... > Cross section - Circle > Outer diameter:
58 > OK
Note:
Note Always the socalled neutral fiber has to be defined for the
cross section, except the definition of the cross section by Circle.
Circle In
this case the outer diameter will be automatically converted to the
neutral fiber.
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It is possible to influence the position of the cross section relative to
the tube axis. This can be done using the field Cross section:
Axis pos: Input boxes may be used to specify the position
of the tube axis relative to the center of the cross section
defined. If these boxes are empty, or if both boxes have the
value 0, the tube axis is positioned to pass through the center of the cross section. If a x and/or yvalue is input, the
tube axis is positioned accordingly with respect to the center of the cross section of the tube.
Ref X: This option is useful only if the cross section is noncircular. The cross section can be rotated around the tube
axis by the specification of a vector.
For Lesson 1, it is not necessary to define either Axis pos, or Ref X..
Here it is possible to move the position of the tube in x, y and/or
zdirection.
In the field Properties, material properties of the tube must be
specified.
Thickness: Thickness of the tube wall. Although this value
is specified when starting up the Input generator, it may be
modified here.
Material: The user may select an appropriate preexisting
material data file from the available material database
(Import), or set up the material data by specifying all of the
required material properties (Input). Either way, the specified material characteristics may be reviewed by clicking
on the View button.
Rolling direction: Here the rolling direction of the tube
needs to be specified. The rolling direction may be either
Axial or Circumferential.
Definition of thickness and the material of the tube
Properties > Thickness: 1.2 > Material: FeP04_1 > Rolling direction: Axial
Tube
After the inputs for the tube are finished the page tube should
appear as shown in Fig. 1.22.
24

Fig. 1.22
Inputs for the tube on the Tube page

Input generator: Lube
On this page a coefficient of friction for all defined tools is specified
(Fig. 1.23):
Constant: Friction is specified with a constant coefficient
for all defined tools. It is possible to select predefined values with the buttons Special lubrication, Standard and
Clean. If User defined is selected, an input is necessary.
Table: It is possible to define different coefficients of friction for each tool.
Note:
Note Predefined/default values may be modified in the file AutoForm.cfg, located in the AutoForm software installation directory.
25

Fig. 1.23
Input generator: Lube page

Definition of the coefficient of friction
Lube
Lubrication > Constant > Constant: User defined: 0.1

The completed Lube page should appear as shown in Fig. 1.23.
Input generator: Process
The process step hydroforming is predefined on the page Process
as standard.
26

Fig. 1.24
Input generator: Process page

For the present simulation, additional process steps must be
defined. Therefore it is necessary to add process subpages under the
page Process.
Process
Add process step ...

The dialog Add process step appears (Fig. 1.25)
27

Fig. 1.25
Dialog: Add process step

There are three different types of process steps in AutoForm
Hydro:
Prebending: This type is used to simulate prebending processes.
Forming: All forming processes, except the prebending,
may be simulated using this type of process.
Annealing: Using this type, an annealing process step may
be defined.
Note:
Note The appearance of a new process subpage depends upon
the type of process selected to be specified. In some cases, no
user inputs are required beyond selection of that process type.
Selection of process step Prebending
Add process step > Type of process step: Prebending
The dialog Add process step changes its appearance (Fig. 1.26)
28

Fig. 1.26
Dialog: Add process step,

step Type: Prebending
Further inputs cannot be specified in this dialog. Preforming may
be simulated only as the first step and can only be defined once at
the beginning of a simulation.
With Add process step a new process step subpage will be added
under the page Process. The name of this new process step may be
changed; also, it is possible to define if the start (Start locked) or the
end (End locked) of the tube should be locked when simulating
prebending.
Note:
Note Prebending of the tube is simulated in this process step in a
single increment. This process step allows the computation of thickness and hardening distribution only, and not changes in the tube
cross section.
For Lesson 1 predefined/default inputs are used. The page for the
Prebending should now appear as shown in Fig. 1.27.
29

Fig. 1.27
Inputs for Prebending on the Process page

A new process step has to be defined for closing the tools.
Add process step ... > Add process step > Type of process step:
Forming
Process
Dialog Add process step looks as shown in Fig. 1.28.
30

Fig. 1.28
Dialog box: Add process step,

step Type: Forming
For this type of process step it is possible to specify further inputs in
the dialog Add process step:
Forming step default settings: The settings of a previously defined process step (Use settings of forming step:)
may be taken over, or standard defaults (Use default settings) can be selected.
Insert position: In this field the position of the new process
step is determined. One of the existing process steps has to
be identified. After this, it is necessary to specify whether
the new process step should be inserted before (Insert
before) or inserted after (Insert after) the selected process
step.
Further inputs in the dialog box Add process step (see Fig. 1.28):
Add process step > Use default settings > Insert before >
hydroforming > Add process step
A new subpage (hydroforming2) is added under the page Process.
The following inputs need to be specified here:
Name: In this field the name of the process step must be
entered.
Type: The process step Forming has the following subtypes:
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Preforming: Used to simulate preform operations (except
for prebending) or the closing of the tools without fluid
medium. This is the default for the process step Forming.
Hydroforming: The hydroforming process (forming with
fluid medium) may also be defined here. There are different ways of specifying a hydroforming process step, as will
be explained during the description of the process step
Hydroforming.
Note:
Note The subpage changes its appearance depending on the
type of the process step Forming selected.
Inputs for the new process step
hydroforming2 > Process step > Name: closing > Type: Preforming
Process
The subpage for this process step should look like shown below:
Fig. 1.29
Inputs for the process step Forming on the page Process

32

Further specifications refers to the tool control and the defaults for
time:
Tool Control: All defined tools are listed (in case not all
tools are shown, the button Show all must be pressed in/
turned on). Three control mode possibilities are available
for each tool.
Non-active: Tool is not used during this process step.
Stationary: Tool is active but stationary during this process
step.
Displcmnt: Tool moves during this process step. A velocity needs to be specified for this tool.
Duration: Here the duration of the process step is specified.
Until time: The time measured from start of simulation
until completion of this process step.
Until closure: Time needed to close two tools against one
another is established automatically based on contact
between these tools.
During time: The time measured from start of this process step until completion of this process step.
Following inputs for tool and timecontrol should be taken specified:
Process
closing > Tool control >

upper_die > Control mode: Displcmnt > Forming step - tool setup
> Velocity: 1 > Set
lower_die > Control mode: Displcmnt > Forming step - tool setup
> Velocity: 1 > Set
Duration > During time > Time: 10
Note:
Note The duration of the process step depends on the distance of
the tools and the selected velocity. With a distance of 20 mm
between upper and lowerdie, and a specified velocity of 1 for
both tools, the duration of movement of both tools towards one
another is 10 s.
The subpage for the process step closing should appear as shown in
Fig. 1.30 upon completion of inputs.
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Fig. 1.30
Inputs for closing under the page Process

Hydroforming is defined as the last process step. When opening the
input generator a process step hydroforming is already predefined,
and must be modified for this lesson.
The type of this forming process step is hydroforming (see above).
This process type offers the following options to control of load
(fluid pressure) evolution:
Pressurecontrol: The evolution of pressure is specified.
Volumecontrol: The desired change of volume is specified and the required pressure evolution is calculated during the simulation.
Heightcontrol: The approximate radial expansion of the
tube has to be defined. The required pressure evolution is
calculated during the simulation.
34

Note:
Note This process subpages appearance depends on the
selected load control method. Inputs specific to the load control
option chosen need to be provided.
In this lesson hydroforming will be done using an increasing pressure during the process. This option (Hydroforming, Pressure) is
predefined for the type Hydroforming.
Further inputs for tool and pressure control as well as the specification of the time must be completed.
Process
hydroforming > Tool control > Show all > upper_die > Control
mode: Stationary > lower_die > Control mode: Stationary
Inputs for the process of pressure must be specified in the field
Hydroforming. Clicking on the button No pressure starts up the
dialog box Pressure (Fig. 1.31).
Fig. 1.31
Dialog box: Pressure

For pressurecontrolled processes, there are two ways to define
pressure:
End p: The end pressure has to be specified.
Time variable: The increase of pressure is defined as
dependent on time.
Note:
Note Pressure inputs are made in N/mm. Options available in this
dialog box depend on the particular pressure input mode chosen
(End
End p,
variable), and may require additional inputs.
p Time variable
35

In this lesson the end pressure (at end of process step) is specified.
Use of the time variable pressure option is described in Lesson 3.
Pressure > End p > Value: 70 > Set
Time input also needs to be completed as follows:
Process
hydroforming > Duration > During time > Time: 70

The subpage for the process step hydroforming should appear as
shown in Fig. 1.32 upon completion of all above inputs.
Fig 1.32
Inputs for hydroforming on the page Process

This completes the input of process parameters and description for
this simulation. Inputs under the Control page are reviewed below.
36

Input generator: Control
Fig. 1.33
Input generator: Control page

Inputs on this page (Fig. 1.33) may be numerical (Main), or may be
a selection of result variables (Rslts).
Default settings may be used over for Lesson 1 except for the following changes.
Control
Main > Restart/post output > WriteRestart (switch off)

Rslts > Contact results > Contact distance above (switch on)
All necessary inputs are now complete, and the simulation may be
started, after savings the inputs.
The simulation will be saved under the name that was entered in
the dialog box New file. The Save as option may be used to save the
37

inputs to a file with a different name. The user may save the input
data from time to time to avoid loss of data in the event of crash of
the workstation, loss of power, etc.
Input generator
File > Save

Job > Start simulation/View log
The window Start job appears (Fig. 1.34).
Fig. 1.34
Window: Start job

Only one simulation may run at any time. Additional simulations
may be set up and queued using the Queue option at the bottom of
the Start job window. These additional simulations may be added
either to the end or start of the current queue.
The simulation can be started by clicking on the button Start.
Start job > Program: afhydro_3.1 > Start
Computed results are appended progressively to the input data
geometry, process parameters, control parameters saved in the
38

simulation file specified in the New file input box. Currently available simulation results may be viewed at any time after starting the
simulation by reopening the simulation file (File > Reopen) in main
display.
After the entire simulation is completed, the window Start job
should be closed using the Dismiss button.
Analysis of results
In the following the analysis of the most important result variables
will be discussed.
Open the *.sim file after the solver finished the calculation.
User interface
File > Reopen

Go to the end of the computed simulation:
User interface
Time > hydroforming

Note:
Note This can also be achieved with the combination of keys Ctrl
E.
There are different ways to display result variable:
Using icons: A subset of the computed results (Thickness,
Thinning, ...) may be displayed by using corresponding
icons displayed on the right side of the main window (Fig.
1.35).
Results menu: All selected result variable are listed under
Result variables in the Results menu (Fig. 136).
Fig. 1.35
Icons for the result variables

39

Fig. 1.36
Result variables pulldown menu

Formability
The result variable Formability displays the strain state at different
locations on the formed tube/sheet (based on the Forming Limit
Diagram FLD), and gives the user an overall picture of formability. Different colors are used to denote the following qualitative
types of strain states.
Cracks: Areas of cracks. These areas are above the Forming
Limit Curve (FLC) of the material used.
Excess. Thinning: In these areas thinning is higher than
the acceptable thinning level (default value for steel 30%).
Risk of cracks: These areas may crack. By default this area
is within a 20% zone below the FLC.
Safe: All areas which have no defects wrinkles, thinning
or cracks.
Insuff. Stretching: Areas which do not have enough strain
(default 2%).
Wrinkling tendency: Areas where wrinkles might appear.
In these areas the material has compressive stress but no
compressive strain.
Wrinkles: Areas where wrinkles can be expected, depending on geometry curvature, thickness and tool contact.
Material in these areas has compressive strains.
40

Display of the result variable Formability
User interface
Results > Result variables ... > Formability > Dismiss

or
Select icon Formability.
Display of the result variable Formability in the main display (Fig.
1.37).
Fig. 1.37
Display of the result variable Formability in the main display

In this example cracks can be expected on one side of the dome. On
the opposite side, there exists the risk of cracks (Fig. 1.37).
The defaultvalues of result variable Formability can be changed in
the following menu:
41

User interface
Results > Formability ...
Fig. 1.38
Dialog: AutoForm - Formability

The small plot shows the different strain regions/states with respect
to the FLC.
Thinning
Another result variable that is often used is the percentage thinning
of the material (Thinning).
Display of the result variable Thinning in the main display:
Results > Result variables ... > Thinning > Dismiss
User interface
or
Select icon Thinning.
42

Display of the result variable Thinning in the main display (Fig.
1.39).
Fig. 1.39
Display of the result variable Thinning in the main display

A scale is displayed in the lower part of the main window with a
range of 30% thinning (-0.3) to 10% thickening (0.1) colored from
yellow to green (depending on the use color settings). The exact
thinning level at any location on the formed tube/sheet may be displayed by clicking at that location on the tube/sheet (in the main
display) using the right mouse button. Esc removes the labels from
the display.
To find the maximum thinning and the maximum thickening of the
part use the following options:
User interface
Results > Show max

Results > Show min
43

Fig. 1.40
Display of the result variable Thinning with min and max values in
the main display
Note:
Note The labels for max and min cannot be removed with the key
Esc.
Esc They have to be switched off by using Results > Show max and
Results > Show min as toggle switches.
To analyze the areas with high values for thinning the range of the
Thinning scale must be changed.
Results > Ranges ...
User interface
The dialog AutoForm Min/Max Editor appears.
44

Fig. 1.41
Dialog: AutoForm Min/Max Editor

Note:
Note The AutoForm - Min/Max Editor may also be accessed from
the Results menu in the user interface: Results > Result variables:
Ranges.
Ranges
Min/Max Simulation: Use min and max values of the
whole simulation.
Min/Max Increment: Use min and max values of the current increment.
Simulation default: Use default min and max values.
Manual: Use user defined min and max values.
Change the values for the scale manually:
AutoForm Min/Max Editor > Manual > Min.: -0.4 > Max.: -0.2 >
Return > Dismiss
Display should correspond to Fig. 1.42. All areas with less than 20%
thinning are displayed in green (depending on the chosen color settings).
45

Fig. 1.42
Display of the result value Thinning with min value 0.4 and max
value 0.2.
0.2
Contact distance above
With this result variable the distance of each element to the surfaces
of the tools is displayed. Thus it is possible to check if the tube is
formed out at the end of the simulation, i.e. if it has contact to the
tool everywhere.
If this is not the case, the pressure must be increased or the radii
have to be increased.
Results > Result variables ... > Contact distance above > Dismiss
User interface
The range of the scale may be modified to obtain a more meaningful

display:
Results > Ranges ... > Manual > Min.: 0 > Max.: 1 > Return > Dismiss
User interface
The display should correspond to Fig. 1.43.
46

Fig. 1.43
Display of the result value Contact distance above with min value 0
and max value 1
You can see that the part is not formed out completely in the area of
the dome, in particular at the radii in this region.
Simulation predicts cracks in the area of the dome when using the
load control method specified here. In Lesson 2, it will be attempted
to prevent splitting by trying to push material into the forming
zone.
47
Lesson 2: Specification of Axial Tools and their Movement
6. 2 Lesson 2: Specification of Axial Tools and their Movement

Building on the simulation from Lesson 1, we show in this chapter how to improve the
result (cracks within the area of the dome).
For this, the existing simulation from Lesson 1 is read in. Since the formability within the
area of the dome is exhausted and results in cracks, to afterpush over tried directed
material into the transformation zone. This is implemented by axial tools ( slide gate
valves), which are to be defined as new tools. In the hydroforming process step, these
redefined axial tools must be considered and the axial tool movement should be
determined.
During the following analysis we see that the results (among other things regarding the
cracks) could be improved substantially (Fig. 2,1).
Fig. 2.1
Calculated part lesson 2
Read in a simulation
For this example, an existing simulation is used and modified as
required. For this a prepared *.sim file is available, which is based
on Lesson 1.
File > Open
User interface
The dialog opens with Select a file (Fig. 2.2).

48

Fig. 2.2
Dialog: Select a file

Select the following sim file in the dialog Select a file:
Files: hy_lesson_02.sim > OK
The geometry from Lesson 1 is shown in the main window and the
input generator for a Hydro simulation is opened.
49

Fig. 2.3
Geometry in the user interface

Some modifications in the input generator must be made now.
Modifications in the Input generator

The title for the new simulation can be modified.
Title

After this, you can continue to work on the Tools page.
Here the axial tools must be defined, with which the material is to
be moved directly into the transformation zone.
As mentioned in Lesson 1, only an axial tool can used for the start of
tubing, Axial start, and an axial tool at the tube end, Axial end has
to be defined.
Note:
Note The axial tools are created automatically. It is not possible in
the present version to define your own geometry for the axial tools.
50

Create the axial punch:
Tools
Add tool ... > Add tool > Axial start > Use default setting > Add
tool
A new tool was defined of the type Axial start. Now, the name must
be modified:
tool3 > Tool name > Name: axial_start > Enter
Further specification are not required here.
Note:
Note The working direction is set to standard by default. This working direction is then the direction (curved) of the tubing axle. In
addition, it is possible to define for the working direction a vector
(dx
dx dy dz
dz).
The second axial tool is similarly created:
Tools
Add tool ... > Add tool > Axial end > Use default setting > Add tool
> tool4 > Tool name > Name: axial_end > Enter
Thus, the axial tools are defined. Further specification must be only
given now on the Process page.
On the Process page, only the process step hydroforming has to be
redefined and must be selected.
The redefined axial tools are set by default to Non active and must
be all inserted with Show.
First, the tool control for axial_start is defined:
Process
hydrofoming > Tool control > axial_start > Control mode: Displcmnt
51

The dialog Forming step - tool setup appears, in which a constant
rate (Constant velocity) or a shift in dependency of the time (Time
variable displacement) for the axial tool can be selected for
axial_start (Fig. 2.4).
Fig. 2.4
Dialog: Forming Step tool setup

Note:
Note In order to check for which axial end the tool attacks b, this
tool can be displayed in the main window, by clicking on the button named axial_start on the bottom right in the main window. This
applies similarly to all other tools.
Define the velocity for the axial tool axial_start:
Forming Step - tool setup > Constant velocity > Value: 0.01 > Set
Note:
Note Option Time variable displacement is explained in lesson 3.
Thus the control inputs of the tool axial_start are completed. Now
the specification for the tool axial_end will be defined:
hydrofoming > Tool control >
axial_end > Control mode: Displcmnt > Forming Step tool setup
> Constant velocity > Value: 0.1 > Set
Process
Thus the specification on the Process page is finished.
52

The page for the process step hydroforming should look as in Fig.
2.5 now.
Fig. 2.5
Specification for hydroforming on the Process page

From the Control page, make sure the WriteRestart option is
switched off and under Rslts the post variable Contact distance
above is switched on
Now the simulation can be started:
Input generator
File > Save

Job > Start simulation ... > Start job > Program: afhydro_3.1 > Start
After the calculation is complete, the *.sim file is reopened and the
results can be analyzed. Close the Start job window with Dismiss.
User interface
File > Reopen

Time > hydroforming
53
Analysis of the simulation results
Formability
First the simulation is examined with the Formability criterion. The
post variable is activated by clicking the Formability button on the
icons menu located on the right side of the main window (moving
the mouse over each icon shows the label).
It is clearly seen that the critical areas of the dome are now no
longer at risk of splitting (Fig. 2.6).
Fig. 2.6
Representation of the post variable Formability in the main display
54

Thinning
Now the second post variable Thinning will be analyzed. The Icon
Thinning is selected.
From the Thinning plot, it is clear that an improvement of the result
has been achieved by the axial tool movement (Fig. 2.7).
Fig. 2.7
Representation of the post variable Thinning in the main display

Contact distance above
The formingout of the pipe can be checked with the Contact distance above result criteria:
User interface
Results > Result variables ... > Contact distance above > Dismiss
Results > Ranges ... > Manual > Min.: 0 > Max.: 1 > Return > Dismiss
55

The representation in the main display should look as in Fig. 2.8:
Fig. 2.8
Representation of the post variable Contact distance above in the

main display
It can be seen that the formingout the pipe has been improved by
the axial tool movement. The pipe is almost completely formed out.
There are only certain small areas in the dome, which have a small
distance of the pipe to the tool surface.
Finally, the Forming Limit Diagram is to be analyzed.
Forming Limit Diagram
The Forming Limit Diagram (FLD) describes the failure of the sheet
metal due to cracks. In the FLD the Forming Limit Curve (strain
states above those failure/cracks are detected) is represented as a
black curve. Into this diagram, all finite elements of a simulation
with the two main strain results (major and minor) are shown. So
one can judge the robustness of a reforming process also visually in
this diagram.
56

This diagram is activated with the following instruction in the main
window:
User interface
Results > FLD ...

By selecting Show all (on the top right), all the elemental strains are
shown in this diagram (Fig. 2.9). In the current example, all strains
are situated below the border deformation curve. This indicates that
the process is quite safe and robust from a formability standpoint.
Fig. 2.9
Representation of all finite elements in the forming limit diagram at

the end of the forming process
It is also possible to plot the colors of the post variable Formability
in the forming limit diagram:
AutoForm FLD > Diagram > Formability
57

The representation is then as in Fig. 2.10.
Fig. 2.10
Representation of all finite elements in the forming limit diagram

with the colors of the post variable Formability
The window AutoForm - FLD is closed with Dismiss.
The user interface can be closed as follows:
File > Quit or hot keys Ctrl Q
User interface
58
Lesson 3: Definition of Timedependent Pressure and Tool Control
6. 3 Lesson 3: Definition of Timedependent Pressure

and Tool Control
Tube hydroforming requires numerous process steps for manufacturing: The semi finished tube undergoes prebending, annealing and hydroforming with timevariable
pressure increase and axial tool displacement. To achieve this in simulation, it is necessary to define lateral and axial tools first. Next, we need to specify prebending and
annealing. Finally, it is necessary to add timepressurecontrol and time variable tool
movement.
Fig 3.1
Part geometry
Creating a new project
Meshing and import of CAD geometry
The CAD tool data for this example is provided in IGES format.
Geometry generator > File > Import ... > Import geometry > Format:
IGES > OK > Select a file > Files: hy_lesson_03_tools.igs > OK
This opens the meshing dialog:
59

After meshing, the full tool appears in the main display. Close the
Geometry generator:
Geometry generator > File > Dismiss
Input generator data
User interface
Model > Input generator > Simulation type > Hydro

For this example please use an initial wall thickness of 1.2 mm.
Simulation type > Tube thickness: 1.2 > OK
Title

In case the semi tube is not formed by tool closure, it is not necessary to define the above and below tools. Only one (closed) tool is
sufficient.
Lesson 3 will contain one lateral tool only.
Definition of a lateral tool:
Tools
Geometry > Reference ...

In the main window, select all faces using the right mouse button
(Fig. 3.2) and open the Reference tool geometry dialog using Activate.
60

Fig. 3.2
Faces for the lateral tool

Fig. 3.3
Input for lateral moving tool on Tools page

61

Please use the default settings for tool working direction and stiffness (Fig. 3.3).
Definition of axial moving tools:
Tools
Add tool
Add tool > Axial start > Use default setting > Add tool
Please use the default settings for tool working direction.
The last remaining tool is axial_end. For this definition, follow the
procedure described for tool axial_start accordingly.
Tools
Add tool
Add tool > Axial end > Use default setting > Add tool
tool3 > Tool name > Name: axial_end > Enter
Please use the default settings for tool working direction. This completes the entries on Tools page for Lesson 3.
Enter the data for the semi finished tube: Tube centerline, outer tube
diameter, material data, etc.
The tube centerline for this lesson is provided in IGESformat
which can be imported as follows:
Tube
Axis > Import ...

Import line (s) > Format: IGES > OK > Select a file > Files:
hy_lesson_03_axis.igs > OK
After meshing is complete, select the tube centerline in the main
window using the right mouse button (Fig. 3.4).
Select curve > OK
62

Fig. 3.4
Center axis
This example features a circular cross section. Therefore, definition
can be achieved using the tube outer diameter.
Tube
Cross section > Circle ...

Cross section - Circle > Outer diameter: 51 > OK
63

Tube position and material (FeP04_1) are according to default values (Fig. 3.5).
Fig. 3.5
Input data on Tube page

Lube
Lubrication > Constant > Constant > User defined: 0.15

Next, define process steps prebending, annealing and tube hydroforming.
Prebending
Add process step > Type of process step > Prebending > Add process step
Process
64

Process
Prebending > Process Step > Type: Prebending > End locked
Annealing
After prebending, define the process step annealing. This stress
relieving procedure may be added after each forming process.
Annealing provides better material forming capabilities for the
main forming process. For calculation purposes, this is achieved by
resetting stresses and strains in the part, yet saving the tube thickness values. You may also change the material properties during
annealing.
Fig. 3.6
Definition of annealing
Initial material: Base material (before annealing)
New material: New material data (after annealing)
Upon working with defaultvalues, AutoFormHydro will calculate with the rvalues data. Optionally you can choose a material
65

from the AutoForm database or create a user defined material (e. g.
via Input on Tube page) or by file import.
View: Displays stressstraincurve, forming limit diagram
and materials rvalues.
Import: Import of a material file (*.mat)
Defining the annealing process:
Add process step > Type of process step > Annealing > Insert position > hydroforming > Insert before > Add process step
Process
Please use default values for annealing (Initial material, New material).
Tube Hydroforming
The main, final process step is hydroforming.
hydroforming > Process step > Type: Hydroforming > Pressure
Tool control > Show all > die > Control mode: Stationary
Process
Axial tool movement (axial_start and axial_end) is described by a

function of time and displacement.
hydroforming > axial_start > Control mode: Displcmnt
Forming step - tool setup > Time variable displacement
Pressing the button Time variable displacement activates the box
Time - Displacement - Table in dialog Forming step - tool setup
activated.
66

This allows for a definition of tool movement dependent on time.
Fig. 3.7
Dialog: Forming step - tool setup

Add: Allows for definition of data sets (Time - Displacement).
From start: The input is defined for beginning of the process. If the data is not sufficient for the entire process step,
the pressure value will be kept constant until end of process is reached.
From end: If pressure is known at the end of the process,
the definition may start from there. Input data in the box
will start at the end of the process and calculate backwards.
At end: In this case the pressureline will be used in the
defined direction. However, the final value is moved
towards the ends of the process step. It may happen that
the pressureline is unknown at the beginning. In this case,
the first pressure value will be used until timecontrol is
activated.
For this lesson please use the following settings in the Forming step
- tool setup dialog box:
Time: 0 > Displacement: 0
Time: 10 > Displacement: 4 > Add
Time: 100 > Displacement: 5 > From start > Set
67

For axial_endtool use data according to tool movement of
axial_start.
hydroforming > axial_end > Control mode: Displcmnt
Forming step - tool setup > Time variable displacement
Finally, enter the time controlled pressure increase. The increase of
pressure in the active media is defined similar to the way you have
specified the axial tool displacement.
Process
hydroforming > Hydroforming > Pressure: No pressure

Pressure > Time variable
Pressing the button Time variable activates the field Time variable
pressure in the Pressure window. This allows for definition of pressure increase as a function of time (Fig. 3.8).
Fig. 3.8
Dialog: Pressure
Please use the following values as input:
Time: 0 > Pressure: 0
Time: 10 > Pressure: 10 > Add
Time: 100 > Pressure: 100 > From start > Set
68

Note:
Note You may use the same time steps for pressure increase and
displacement of axial cylinders. In this case, process control will be
by pressuredisplacement.
Finally, enter the process time for forming. By default, this is 500
seconds. For this process, adjustment is necessary because tool displacement was set to 100 seconds during timepressuredevelopment.
Process

The complete hydroforming process should look like Fig. 3.9 now.
Fig. 3.9
Definition of hydroforming process

These default values can be used for calculation (Fig. 3.10).
69

It is recommended to switch off the option WriteRestart in Main.
Switch on Contact distance above under Rslts.
Control
Fig. 3.10
ControlMain page
Start of Simulation
File > Save
Input generator
Job > Start simulation/View log

70
Lesson 4: Simulation of Hydroforming using Counterpunch
6. 4 Lesson 4: Simulation of Hydroforming using Counterpunch

A tube is formed by prebending, followed by inner pressure forming with time dependent pressure increase and axial tool movement. At first the lateral tool, counter tool
and axial tool are defined. Then the forming process is specified by a time dependent
pressure control and tool movement.
Fig. 4.1
Part geometry
Preparation of simulation
Open a new simulation file:
Geometry generator opens.
Importing and Meshing the CAD geometry
The CAD tool data for this example is provided in IGES format.
Geometry generator
File > Import ...

Format: IGES > OK > Select a file > Files: hy_lesson_04_tools.igs >
OK > Program: afmesh_3.1 > OK
71

Close the Geometry generator.
Geometry generator
File > Dismiss

Generate simulation input
Model > Input generator
Simulation type > Simulation type: Hydro > Tube thickness: 1.2 >
OK
The tube shall have a wall thickness of 1.2 mm in this example.
Title

Definition of lateral tool
In this example only one lateral tool (die) is defined.
Tools
die > Geometry > Reference ...

Reference tool geometry > Pick faces
Now the necessary patches for tool will be selected (Fig. 4.2).
Ctrl X (View from +X)
Select patches in main display with right mouse button Shift key
and activate patches with option Activate in Reference tool geometry menu.
72

Fig. 4.2
Necessary patches for lateral tool

Default values for working direction and stiffness will be accepted
(Fig. 4.3).
73

Fig. 4.3
Inputs for lateral tool on Tools page

Definition of counter tool
Use of a counter tool is necessary in hydroforming process, if special features are to be formed out of tube, e.g. a Tform. The forming
of these features and the material flow can be controlled with a
counter tool. Cracks would occur if such counter tools were not
used.
Next is the setup for the counter tool.
Tools
Add tool
Add tool > Type of tool: Lateral > Default tool settings: Use settings of tool: die > Add tool
For this tool name, the geometry working direction must be
defined.
74

Tools
tool2 > Tool name > Name: countertool > Enter

countertool > Geometry: Reference ...
Reference tool geometry > Pick faces
Select necessary patches for the counter tool (Fig. 4.4).
Select patches in main display with right mouse button Shift key
and activate patches with option Activate in Reference tool geometry menu.
Fig. 4.4
Necessary patches for counter tool

Working direction of counter tool must be defined. Two possibilities exist:
In the field named Working direction a vector can be specified (Fig. 4.5).
With the Copy from option a vector can be imported from
CAD (Fig. 4.5).
75

Fig. 4.5
Inputs for counter tool on Tools page

In this example the Copy from option is used. To use Copy from
option, curves must be imported first. Two possibilities exist:
Use of Curve managers
Import of curves on Tube page option Axis Import
Option 1: Use of Curve managers
Model > Curve manager ...
Curve manager opens. (Fig. 4.6)
Curve manager > File > Import ...
76

Fig. 4.6
Curve manager
Import lines menu opens.
Import line(s) > Format: IGES > OK > Select a file > Files:
hy_lesson_04_axis.igs > OK > Program: afmesh_3.1 > OK
Imported lines are displayed in main display and in Curve manager
as Curve 1 and Curve 2. These two lines are the center line of the
tube and working direction of the counter tool respectively.
Close Curve manager.
Curve manager > File > Dismiss
Use Copy from on Tools page of Input generator to define working
direction.
countertool > Working direction: Copy f. ...
Select curve menu opens.
Select green line with right mouse button. In Curve manager it can
be seen that green line is Curve 2.
Select curve > OK
AutoForm - Question menu for determination of orientation opens.
AutoForm - Question > Keep
Option 2: Use Import option on Tube page.
Tube
Axis > Import

77

Import line(s) > Format: IGES > OK > Select a file > Files:
hy_lesson_04_axis.igs > OK > Program: afmesh_3.1 > OK
Imported lines are displayed in main display and in Curve manager
as Curve 1 and Curve 2.
Close Select curve menu.
Select curve > Cancel
Use Copy from to define working direction.
countertool > Working direction: Copy f. ...
Select curve menu opens.
Select green line with right mouse button. In Curve manager, it can
be seen that green line is Curve 2.
Select curve > OK
AutoForm - Question menu for determination of orientation opens.
AutoForm - Question > Keep
Counter tool must be positioned using Move.
countertool > Working direction > Move: -10
Inputs on Countertool page are completed.
Definition of axial tools
Add tool
Add tool > Type of tool: Axial start > Use default setting > Add
tool
Tools

The tool tool3 has been renamed axial_start.
axial_start > Working direction: Automatic
Last tool to define is axial_end. Procedure is the same as for
axial_start.
78

Tools
Add tool
Add tool > Type of tool: Axial end > Use default setting > Add tool
tool4 > Tool name > Name: axial_end > Enter
axial_end > Working direction: Automatic
Inputs for tools are completed.
Tube center line must be specified.
Curves are already imported. Tube center line can be defined using
Copy from option.
Tube
Axis > Copy from

Select tube center line with right mouse button.
Select curve > OK
Another input is the tubeprofile. In this example, it is a circular
tube, so the profile can be specified by specifying the outer diameter.
Tube
Cross section > Circle ...

Cross section - Circle > Outer diameter: 60 > OK
79

Default values are taken for the position and material (FeP04_1)
(Fig. 4.7)
Fig. 4.7
Inputs for tube on Tube page

Lubrication > Constant > Constant: User defined: 0.1
Process steps Prebending and Hydroforming must be defined.
Prebending
Process

Add process step > Type of process step > Prebending > Add process step
prebending > Process Step >Type: Prebending: End locked
80

Attention:
axial_start)
Attention After Prebending,
Prebending the free end of the tube (axial_start
axial_start is
not perpendicular to the tube center line. This is due to bending of
the tube. Therefore, the tube center line must be shortened to
avoid problems in the following simulation.
Tube
Axis > Edit ...

Curve editor opens and the tube center line is displayed in main
display.
User interface
Ctrl X (View +X)

Select last point with the right mouse button (Fig. 4.8).
Fig. 4.8
Display of tube center line in edit mode

Coordinates of selected point are displayed in Curve editor.
Modify ycoordinate (Fig. 4.9).
Curve editor > Base > Y: 10 > OK
81

Fig. 4.9
Curve editor
Hydroforming
Now Hydroforming must be defined (Fig. 4.10). Select subpage
hydroforming on the Process page.
Process
hydroforming > Process step > Type: Hydroforming: Pressure

Tool control > Show all
die > Control mode: Stationary
Tool movement of counter tool and axial tool (axial_end) are
described by a timedependent displacement function.
Tool movement of axial tool axial_start is not preferred for this process since geometric. Wrinkles might occur.
countertool > Control mode: Displcmnt
Forming step - tool setup >Time variable displacement
Buttons Time variable displacement activates field Time - Displacement - Table in Forming step - tool setup menu, so that tool
movement can be specified as being timedependent.
Use following values:
82
www.alghaform.com

Repeat for tool axial_end.
axial_end > Control mode: Displcmnt
For this lesson, the following values in the Forming step - tool
setup dialog are should be defined:
Use following values:
Tool axial_start is set to Stationary:
axial_start > Control mode: Stationary
Last input is the timedependent pressure function.
hydroforming >Hydroforming > Pressure: No pressure
Pressure >Time variable
Button Time variable activates the Time variable pressure input
field.
Time: 0 > Pressure: 0
Time: 200 > Pressure: 40 > From start > Set
Duration has to be specified.
83

Fig. 4.10
Definition of hydroforming process

WriteRestart OFF
Contact distance above ON
Start the Simulation
File > Save
Input generator
Job > Start simulation

84

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iletisim: omarer25@hotmail.

AutoFormHydro is an AutoForm Software package for simulation

If shape of the tube cross section is important to simulate accurately

Contents of the Workshop AutoFormHydro

Set up of a Simulation with Linear Pressure History.

Specification of Axial Tools and their Movement . . . . . . . . . . 48

Creating a new simulation file

Opening an existing simulation file

Definition of Timedependent Pressure

Simulation of Hydroforming using a Counterpunch . . . . . . . . 71

Defining geometry of a counterpunch

Lesson 1: Set up of a Simulation with Linear Pressure History

6. 1 Lesson 1: Set up of a Simulation with Linear Pressure

Part geometry lesson 1

Starting up the AutoForm UserInterface

Lesson 1: Set up of a Simulation with Linear Pressure History

Dialog box: New file

Lesson 1: Set up of a Simulation with Linear Pressure History

Geometry generator: Prepare page

Lesson 1: Set up of a Simulation with Linear Pressure History

File > Import ...

Dialog: Import geometry

Lesson 1: Set up of a Simulation with Linear Pressure History

Dialog: Select a file

Dialog box: AutoFormAutomesher interface

Lesson 1: Set up of a Simulation with Linear Pressure History

Error tolerance: Determines the chordal deviation error for

Treat only: Only faces with specified numbers will be

Treat only: Only layers with specified numbers will be

File > Dismiss

Lesson 1: Set up of a Simulation with Linear Pressure History

Working with the Input generator

Start of the input generator

Model > Input generator ...

Dialog box: Simulation type

Window: Simulation type Hydro

Lesson 1: Set up of a Simulation with Linear Pressure History

Input generator: Title page

Lesson 1: Set up of a Simulation with Linear Pressure History

Title: hy_lesson_01 (training, date)

Lesson 1: Set up of a Simulation with Linear Pressure History

Input generator: Tools page

die > Tool name > Name: upper_die > Enter

Lesson 1: Set up of a Simulation with Linear Pressure History

upper_die > Geometry: Reference ...

Window: Reference tool geometry

Lesson 1: Set up of a Simulation with Linear Pressure History

Necessary faces for the tool upper_die

Lesson 1: Set up of a Simulation with Linear Pressure History

upper_die > Working direction > dx dy dz: 0, 0, 1 > Move: -10

Lesson 1: Set up of a Simulation with Linear Pressure History

Inputs for the tool upper_die in the page Tools

Add tool ...

Dialog box: Add tool

Lesson 1: Set up of a Simulation with Linear Pressure History

Add tool > Type of tool > Lateral >

tool2 > Name: lower_die > Enter

lower_die > Working direction > dx dy dz: 0, 0, 1

Lesson 1: Set up of a Simulation with Linear Pressure History

Necessary faces for the tool lower_die

Lesson 1: Set up of a Simulation with Linear Pressure History

Inputs for the tool lower_die in the page Tools

Lesson 1: Set up of a Simulation with Linear Pressure History

Input generator: Tube page