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DYNAFORM 5.8.1 Training Tutorial

Blank Unfolding and Nesting
Descriptions for blank unfolding calculation and nesting process by Coat Hanger part.

I. Create and s

ave database
1. 2. 3. 4. Start up Dynaform 5.8.1. Click File menu and select Save As … (See Figure 1). Enter BSE_(user name)_(date).df as the file name. Click Save to save the database.

Figure 1 Figure 2

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II. Import Geometry
1. Click BSE menu (See Figure 3). 2. Select Preparation, the program will popup the BSE project GUI (See Figure 4). Click OK to enter Preparation dialog. 3. Click File menu and select IMPORT option. 4. Select file location: …/Tutorial1_Hanger 5. Select file: hanger.igs 6. Click OK to import part geometry. 7. The imported model will be automatically added to the sheet toolkit. Meanwhile, the button turns black, which indicates the completion of defining sheet.

Figure 3

Figure 4

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II. Import Geometry

Figure 6 Figure 5

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III. Rename the part
1. 2. 3. 4. 5. 6. Click Parts menu (See Figure 7). Select Edit. Double click on the input box for Name to highlight part name C002V000. Type in the new name HANGER. Click Modify. Click OK to exit Edit Part dialog box.

Figure 7 Figure 8

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IV. Auto-Mesh the surfaces
1. 2. 3. 4. 5. 6. 7. 8. 9. Select BSE Preparation. Select Surface Mesh (See Figure 9). The default Mesher is MSTEP Mesh (See Figure 10). Key in the Max. Size: 2.00 (mm) Click Apply to mesh. Click OK to exit MESH QUALITY CHECK dialog box. Click Yes to accept mesh. Click Exit to dismiss the Surface Mesh dialog box. See Figure 11.

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IV. Auto-Mesh the surfaces

Figure 9

Figure 10

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IV. Auto-Mesh the surfaces

Figure 11

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V. Check and Repair Mesh
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Toggle off Surface (See Figure 12). Click Boundary Display icon(line one, column three)(See Figure 13). Toggle off Elements and Node. Click (free rotation) to rotate the model. Click (clear highlight). Click to display the model in isometric view. Click Auto Normal icon (line one, column two). Select CURSOR PICK PART. Move the cursor to select an element on the model (See Figure 14). Select No to reverse the normal (See Figure 15).

11. Click Exit to dismiss the dialog box.

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V. Check and Repair Mesh

Figure 12

Figure 13

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V. Check and Repair Mesh

Figure 14

Figure 15

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VI. Blank Size Estimate
Click Mstep in BSE Preparation interface (See Figure 16). Click Material to define material in the displayed MSTEP window (See Figure 17). 3. Click None to define material in the displayed Define blank window (See Figure 17). 4. Click Material Library in the displayed material window (See Figure 19). 5. Select CQ (mild) as the material (See Figure 20). 6. Click OK to exit MATERIAL TYPE 36 dialog box (See Figure 21). 7. Click OK to exit Material dialog box (See Figure 22). 8. Enter the blank thickness = 1.20 (mm) (See Figure 23). 9. Click Run Mstep to run Mstep (See Figure 24, Figure 25). 10. Click to open the part display dialog box. Select HANGER and click OK to toggle off the part hanger, with OUT Line displayed only. 11. Click to display blank outline in TOP view (See Figure 25). 12. Click to save the database.
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1. 2.

VI. Blank Size Estimate

Figure 17 Figure 16

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VI. Blank Size Estimate

Figure 18

Figure 19 Figure 20

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VI. Blank Size Estimate

Figure 23

Figure 21

Figure 22

16

VI. Blank Size Estimate

Figure 25

Figure 24

Figure 26

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VII. Blank Outline Management
1. Click Outline button in the Mstep interface (See Figure 27). 2. The blank outline interface window pops up. The program will automatically read in the outline generated by Mstep and add it to the list (See Figure 28). 3. Click New button to create a new Outline 2 (See Figure 29). 4. Click Import line icon and import outline2.igs(See Figure 30, Figure 31). 5. Switch to Outline1 and the current display will be switched automatically. Turn off the Outline2 part. 6. Click to save the database.

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VII. Blank Outline Management

Figure 27

Figure 28

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VII. Blank Outline Management

Figure 30

Figure 29

Figure 31

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VIII.Blank Nesting
1. Click Blank Nesting button in Outline interface. 2. Select nesting type: Two-Up Nesting (the second icon). 3. The program will automatically define Outline as the blank outline for blank nesting. 4. Setup nesting parameters a) Type in Edge Width:2.0 mm in Parameters Group. This parameter defines the shortest distance between part and edge boundary. b) Type in Bridge Span:5.0 mm. This parameter defines the shortest distance between blanks. c) Type in Addendum: 5.0mm. This parameter is used to setup the addendum of the blank. 5. Click Constraints to set the parameters for strips and blanks. Note: These parameters restrict the size of strip and the angle when placing blank on the strip. If these parameters are not defined, the program will calculate the desired nesting result according to the default angle range and width range. In this tutorial, please use the default angle range and width range to calculate. 6. Click Fix Width to adjust the width, input the value of 590 as the nesting width (See Figure 33). 7. Click Apply to start nesting calculation (See Figure 34). 21

VIII.Blank Nesting

Figure 32 Figure 33

Figure 34

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VIII.Blank Nesting
8. View nesting result After completion of nesting calculation, all the possible nesting results are displayed in the results list. The default display in graphic region is the nesting results with the max. material utilization under the default constraint. The user can click on the other results in result list to display them in graphic region. Or return to setup the specific parameters and recalculate nesting. (See Figure 35, Figure 36).

Figure 35

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VIII.Blank Nesting

Figure 36

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VIII.Blank Nesting
9. Output Nest Report The Report button at the bottom of Nesting dialog box has been activated . Click on this button to output nest report (See Figure 37). a) Click Filename to output the specified file name of report. b) Enter Base Material cost: 35 $/kg. c) Enter Extra Material cost: 5 $/kg. d) Enter Scrap Material cost: 2 $/kg. e) Enter Consumables cost: 1 $/kg. Formula for calculating the cost of each blank : Cost of each blank = (Base+ Extra) * weight of each blank – Scrap*(1- utilization)* weight of each blank f) Click Apply button at the bottom of Nest Report dialog box (See Figure 36). The program will automatically write in the report in *.htm format to the specified file, as shown in Figure 38.
Figure 37

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VIII.Blank Nesting

Figure 38

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