Die Structure Optimization

The Die Structure Optimization process is a function used to automatically transfer tool contact forces from stamping analysis to a structural model and an easy step-by-step setup of die structure optimization model.

As you move through the steps at the bottom of the window, you will see the Process Manager updating automatically. As each step is completed, a green checkmark is placed next to the step name.

1.	To launch the process, under the Applications menu, click Die Optimization.

2.	In the Create dialog, select Create New Instance and enter a name in the Process instance name field. Alternatively, you can select Open Existing Instance and browse for that file name.

3.	Click Create.

4.	From the Materials menu, select the type of material to use to define the tool and click Apply.

5.	Select either RADIOSS or LS-DYNA as the stamping solver, and then click Browse to locate the file where the stamping results are stored.

6.	Click Apply. The Process Manager launches HyperView to query the model and create a list of components that are available in the stamping model. Once the results are brought back into HyperForm, you will be able to select which tool to extract the contact forces from.

7.	The next step is to select the tool to extract the contact forces from. Click Apply.

8.	Click the yellow components button. Using the component selector, select the part of the model where you want to map the forces on to and click proceed.

Using linear interpolation, HyperMesh will create the structural loads based on the stamping results. The z position of the part in the stamping model and the die structure need to be in the same position, so check that before moving ahead to mapping.

9.	In the next dialog, create the holding points (constraints). Pick the nodes, constrain the translation and click Apply.

10.	To define the lifting load case, pick the nodes and click proceed.

11.	Define the lifting height in the field (in millimeters, distance away from the approximate center of gravity of the die structure). A force of almost two times weight of the die will be applied in the positive Z direction.

The Process Manager creates and defines all the loads and load cases that are required in order to run the optimization.

12.	In the next step, define which components are considered design and which components are considered non-design. Design components will be considered for a topology optimization. Make this selection in the Status field.

As an option, in the Stress Value field enter a value for a global stress constraint for the Optimization problem.

13.	Click Apply. All properties and materials are created and assigned to the right components.

14.	Next define more parameters for the design variables.

Min Member Size: tells the routine that no structure should have member size of less than 25 mm dimension after an optimization run.

Draw Direction: Adds an additional manufacturing constraint telling the routine that the draw direction is in the z direction.

15.	Click Apply.

16.	Determine the desired target volume. Enter the value for the lowest percentage for the minimum operational volume in the Volume Fraction field. Click Apply.

17.	In the Objective field, make a selection in the drop down regarding want you want to do with this simulation. Click Apply.

18.	Specify a file name to export. Use the Browse button to locate/create a file, and then select either export or export/run.