Tip 9 : 10 TIPS ON UNFOLD

[danielai]

Shared by 3DQuickPress Support Team on 10 TIPS ON UNFOLD.

1. you have to know what types of process the forming is about, flange or stamp. Your case is a stamp process.
2. you have to know whether your part is a deep drawing or forming. If it is a deep drawing part, please turn off the pre-flattening option. The pre-flattening option will use the new version solver which is good to do forming and also forming with undercut. But for deep drawing, the result is not very stable. So better use the old solver, and turn off the pre-flattening option.
3. consider at the step that you want to simulate, how the reverse forming result should looks like and create the initial blank surface. In your case, it has been done good enough.
4. you have to consider how much the part is going to deform during the process. In cases with initial blank, only part of the area is deformed, and the rest is kept untouched, so in the punch part, you only need to select those surface that is going to deform. In cases that is a one step forming, then all surface should be selected as punch part.
5. if the part is symmetric, just done one side of it. Just like what we do in the part send to you. This increase the stability of the result, and reduce the random errors. This is because the mesh generated will not be perfectly symmetric on both sides.
6. the fix boundary should be placed at the location where the punch part is connected to the original part. Just as what we done in the part for you, as at this edge, all mesh elements are not moving.
7. if there is a centre plane where the mesh is going to move along this plane, then set the symmetric plane condition on it.
8. keep the mesh ratio at 5:2 for coarse : fine. This works for most cases. If it still fail, try reduce the mesh variation by reducing the coarse mesh size.
9. start with a coarse mesh first, as this will takes less time in calculation. If it works good, then you can use a finer mesh. But sometimes, finer mesh will fail in calculation. The result for coarse mesh is more stable.
10. remove all holes that is not present in the forming process from the punch part surface. The result will be different when holes exists.