Advanced Training --- PDW NX 1.0.2 Plus. Agenda Day 1 Introduction Part Analysis & Intermediate...

Advanced Training --- PDW NX 1.0.2 Plus Advanced Training --- PDW NX 1.0.2 Plus

AgendaAgenda

Day 1

Introduction

Part Analysis & Intermediate Status Preparation

Process Design Strip Layout & Simulation

Day 2

Die Base Design

Insert Group Design

Standard Part Design

Relief, Pocketing & Clearance

Day 3

Customization – Die Base, Insert Group, Standard Part, etc.

BOM & Others

Day 4 (?) Free Discussion & New Requirement

Introduction --- PDW NX 1.0.2 Plus Introduction --- PDW NX 1.0.2 Plus

Feature Recognition [SMFR]

Project Initialization

Design Setting

Feature Pre-Process

Blank Layout

Scrap Design

Strip Layout

Force Calculation

Die Base Design

Insert Group Design

Standard Part Management

Relief Design

Pocket Creation

BOM

Assembly Drawing

View Manager

Design Tools

Remove Unwanted Part

Patch Hole

Extend Sheet

Trim Part

Clearance Management

UG Basic Curves

UG Extract Curves

UG Sketch

UG Patch Body

UG Unbend/Rebend

UG Form/Unform

UG MetaForm

PDW NX 1.0.2 Plus

• not an official release

• no official CD produced

• download from E-VIS

• big difference --- break through part & feature type limitation (straight brake, free-form, feature-based, dumb body)

Introduction --- Streamlined Design ProcessIntroduction --- Streamlined Design Process

Sheet Part Design Metal PDW Progressive Die Design CAM

• Any CAD System [2D, 3D]

• Any Industry

SMD Feature-Based Model

SMFR

SMD & Modeling

Dumb Body

Build Progressive Die Design Assembly

Unfold Blank

Layout Blank

Product Feature Process

How to Cut-off Scrap

Strip Layout

Simulate Virtual Manufactured Product

Design Die Base

Design Insert Group & Set Clearance

Design Standard Part & Set Clearance

Design Relief for Formed Feature

Generate Pocket

Predict & Balance Force

Set Major Design Parameters

BOM

Assembly Drawing

Component Detailing

Hole Data

Hole Making

Wire EDM

…

Introduction --- PDW Design Assembly Structure & Relation Introduction --- PDW Design Assembly Structure & Relation

Feature Preprocess

Blank Layout

Scrap Design

Strip Layout

Die Base

Insert Group

Standard Part

Strip Layout Simulation

Faces of process

Sheet body

Sheet body

Solid body

Introduction --- PDW Design Change Introduction --- PDW Design Change

ProductExterior boundary Change

Add/remove feature

Hole dimension change

Blank LayoutAdjust blank layout: width, pitch, etc.

Pre-ProcessUpdate Blank

Define new process

Scrap DesignAdjust scraps: remove,

add scrapsStrip LayoutProcess Definition

Pitch

Blank Orientation

Scrap Design

Sheet Metal Part

Remove All

Insert GroupDelete unused inserts,

add new inserts

Part Analysis & Intermediate Status Preparation Part Analysis & Intermediate Status Preparation

Best PracticeUnform Part Form Part to check if there is any feature update fail or part distorted

Unform Part Form Individual Features according to part manufacturing process sequence to check if there is any downstream feature update fail or part distorted

Check if there is multiple solid bodies Blank only wave-link the solid body of unformed part with maximum features

Try to unite them if united body still can unform/form; otherwise just leave them alone.

Intermediate Bending Process:

• If you want to keep tangent length constant (bend radius become larger), use Feature Pre-Process

• If you want to keep bend radius constant (tangent length become larger), divide bend to several segments

Other Intermediate Process (local forming, free-form feature):

• Prepare intermediate geometry and store into part


Case Study

UG NX2.0


Case 1 (u_R_coin_coin.prt)

1 solid body


Case 2 (J_15428284.prt)

7 solid bodies – Unite


Case 3 (U_form_bridge_emboss.prt)


Case 3


Case 3

3 solid bodies

Unite them

Note: also need check if unite will affect part Unform/Form

Can not automatically

get correct Blank,


Case 4 (2_bridge_step.prt)

Best Practice •Save as a new part --- 2_bridge_step_blk.prt

•Use your expertise or other Unform tools (MetaForm, FastBlank, AutoForm, etc. ) to create correct blank

•Assign upper face (punch side) name as “UP_DATUM_FACE”

•Go to the original sheet metal part, remove the parameters of the features and save it.


Case 5 (gh_form_b.prt)

Simplify

SMFR

Wave-link free-form feature solid body

Add SM CUTOUT manually (distance tolerance=0.001)

Divide bend faces for pre-bend

•Create Part


Case 5 (gh_form_b_new.prt) •Create Blank Part --- gb_form_b_new_blk.prt

Unform Self-forming features

Unform Barrel

face name: UP_DATUM_FACE


Case 5 (gh_form_b_new.prt) • Create Intermediate States for Special Barrel

• Save into Different Layers

User can create any geometry to stand for intermediate state


Case6 (demo_part02.prt)• Create Intermediate States of Part

• Create Blank Part --- demo_part02_blk.prt

Unform geometry in 2-sides by using your expertise or other Unform tool (MetaForm, FastBlank or AutoForm)

PDW NX2.0 will also provide an Advanced Tool to unform free-form geometry

UnbendUnbend

face name: UP_DATUM_FACE

UG NX2.0

Process Design Process Design

Case 1

User Defined Process (Interactive Layout)


Case 2



Case 3


Case 3

Remove additional sheet bodies



Case 41. Project Initialization

2. Create Blank in Feature Pre-Process

Module

3. Change display part to <2_bridge_step_blank> part

4. Import Part -- <2_bridge_step_blk.prt> (make sure the orientation is same as the part)

5. Delete the solid created automatically


Case 4 User Defined Process (Interactive Layout)

UG/Patch fail

Manually Refine it – Trim additional portion


Case 5 1. Project Initialization


Module

3. Change display part to <gb_form_b_new_blank> part

4. Import Part -- < gb_form_b_new _blk.prt> (make sure the orientation is same as the part)


Blank LayoutScrap Design


Case 5 UDS (user defined scrap)

Join Face

Extract Edges (work part -- *_nest_*)


Case 5

Sketch

In order to make sure the sketch is same as the blank boundary. Only turn on Coincident

UDS

Scrap

• It is very important to make sure the quality of scrap boundary (no overlap, no tiny curve, no gap, etc.), otherwise, it will cause big troubles in downstream Piercing Insert design (fail to create Cavity Hole)

Notice:

•The scrap which is converted by sheet body can not be split


Case 5 Strip Layout & Simulation User Defined Process (Interactive Layout)

Refine it


Case 6 1. Project Initialization


Module

3. Change display part to <demo_part02_blank> part

4. Import Part -- < demo_part02 _blk.prt> (make sure the orientation is same as the part)


Blank LayoutScrap Design

UG NX2.0


Case 6Strip Layout & Simulation



Case 6Strip Layout & Simulation

Structure Design --- Die Base Structure Design --- Die Base

Best Practice

• Choose a set of die base from Die Base Catalog which is most closer to what you want. You can set thickness of certain plate which you don’t want to “0”, then PDW will remove it for you automatically.

• Change size of plates, thickness, length, width

• Change pattern of screw set, dowel pin set, etc.

• Change size of individual guide post/bush, screw, dowel pin, etc.

• Split any plate if it is necessary

• If some features update fail or some parameters do not work, just go to the part and change corresponding expressions.

• It is very easy to cut some details in die plates by using UG Modeling function


Case 5


Case 6

Structure Design --- Insert Group Structure Design --- Insert Group

Best Practice

• Set Die Base, Simulation invisible

• Design standard inserts by using inserts PDW provided,

Piercing, Mount, Bending (straight bend, angle bend, Z-bend, V-bend), Blanking, Burring, Chamfering, Counter-boring, Counter-sinking, Deburring, Dimpling, Engraving, Forming, Half-cutting, Lancing, Pilot, Lifter, Embossing.

Most of above standard insert groups have been implemented Design Automation (dimension & position)

• For free-form feature, pick the faces, load a Solid Block (rectangular or cylindrical) from Embossing insert group, PDW can automatically centralize it. Change size to meet your needs, then exact faces from Strip Layout or Simulation parts, add some sheets, sew together, trim the block.

• If some features of insert groups fail to update, change related parameter value.

• If dimension automation fail, just change size of insert groups manually, if position automation fail, just use UG Assembly --- Reposition component to adjust it

• If some parameters in UI do not take effect, just go to the part and change corresponding expressions.

• It is very easy to design some details (chamfer, round corner, foot-proof) in insert True Bodies by using UG Modeling function

• We don’t recommend you add details (chamfer, round corner, foot-proof) in False Bodies; the better way is, after pocketing, offset pocket faces for clearance, then add details on the pocket corners.

Note: PDW NX1.0.2 Plus lets you assign different clearance for Piercing Punch going through several plates; PDW NX2.0 will allow you assign clearance for all insert groups and standard parts by using Clearance Management tool.


Case 5 • Piercing Insert

User can pick as many as possible scraps at one time

If user does not load die insert, cavity hole will create in die plate directly

Sometimes, cavity hole can not create automatically because of bad quality of scrap boundary (offset boundary by cutting clearance Extrude fail), in this situation, just use UG Modeling function to create it interactively.

Piercing PunchPiercing Die

Slug Hole Solid in Bottom Backing Plate & Die Shoe

Cavity Hole


Case 5 • Bending Insert

1. Choose correct Bending Type

check Bending Punch

2. Pick “root faces” (bending faces, inside or outside)

3. Load correct Bend Punch & Click Ok

4. Adjust size for each component as you want (False Body as well)

(screw, spring will be automatically removed or added

According to block size)


Case 5 • Bending Insert

5. Check Bending Die

6. Load correct Bend Die & click Ok

7. Some parameters may not be controlled by UI correctly, so you need edit part expressions interactively

8. Add round or chamfer corner for

each block’s True Body


Case 5 • Free-From (Embossing) Insert

If it is closed local forming, you can use Embossing insert to design it automatically; otherwise you need to following steps

1. Go to Embossing page, pick faces of emboss

2. Load a emboss insert and adjust size

3. Extract faces from Strip or Simulation part

4. Extend extract sheet bodies by using UG Extrude and/or Through Curve Mesh (Free form) or other modeling functions according to your requirement

5. Sew them together

6. Use Trim Part function of PDW to trim the punch insert head

7. Same method for die insert

8. Refine corners


Case 5 • Free-Form Insert

Punch Head Die Head

Refined Die Insert (add a foot-proof)


Case 6 • Insert Groups


Case 6 • Insert Groups

Structure Design --- Standard Part Structure Design --- Standard Part

English Catalogs:

• Danly

• Dayton

• Hyson

• Superior

Metric

• Misumi

• Strack

• Dayton

• Hyson

Structure Design --- Relief, Pocketing & Clearance Structure Design --- Relief, Pocketing & Clearance

• Set Piercing Punch clearance for different sections

• go to Clearance Management UI

• pick the face of piercing punch false body

• default clearances will show in UI

• you can change value or assign new clearance

• click Apply

• Pocketing

• Refine pocket details, such as, clearance, corners.

Customization --- Standard PartCustomization --- Standard Part

Standard Library Folder Structure

• $PDIEWIZARD_DIR/standard/english(or metric)/<catalog name>/<part classification>/model parts

data data files

bitmap bitmap files

• In order not to be overwritten by each new PDW release and easily move your own libraries into new PDW version, we strongly suggest that you should create a new catalog name,

• Create a catalog name under $PDIEWIZARD_DIR/standard, such as custom01

• Create subfolder using part classification name, such as punch, die button (optional)

• Create model, bitmap, data folders under above folder


Step_01 Model a Standard Part

You can copy and modify a similar part from existed standard part library or create a new part from scratch

• Set WCS to ABS (origin & orientation)

• Create a datum plane from X-Y plane

• Create top-z plane relative to first plane by TOP_Z offsetting

• Build part from the TOP_Z datum plane, it’s easy to adjust Z-position

TOP_Z

• Create component body and pocket cutting body


Component Body (set partially shaded)

Pocket Cutting Body (yellow color, dashed line font)

Create reference set named “TRUE” and add the component bodies into this reference set

Create reference set named “FALSE” and add the pocket cutting bodies into this reference set

• Add part attribute: “UM_STANDARD_PART=1”

• Put the part into “model” folder


Step_02 Create Bitmaps You can copy and modify a similar bitmap from existed standard part library or create a new bitmap from scratch

You can create bitmap images by many methods, including:• Scanning from catalogs or photographs• Drawing with MS Paint• Exporting or capturing from Unigraphics as a bitmap (.bmp) file

Add the bitmap files into bitmap folder

Step_03 Creating Data File

To create a data file, copy and rename an existing spreadsheet file, then edit the parameter name and data to match your requirement.

Add the data file into data folder


Default parent part, use part attribute name

Position method

Part attribute to be added in this standard part

CATALOG and MATERIAL attribute is for BOM

Also you can add “UM_STANDARD_PART=1” here.

The path of created bitmap file,

you can use relative or absolute path

The part expressions that you want to change in UI


Step_04 Register Part

• Create pdw_catalog.txt file under custom01

• Create a spreadsheet register file file, such as custom01_std_reg.xls/xs4 under custom01

Customization -- Die BaseCustomization -- Die Base

Configuring a die base is just like designing a progressive die without the insert group.

• Step_1 Load a die base

The new custom die base must be based on an existing die base. It’s better to use the DB_UNIVERSAL die base catalog as your base.

• Step_2 Add the standard parts

Click “Add/Edit” component button, it’ll pop up the same dialog as standard part UI.


• Step_3 Save current die base as template

Click this button

When system pop up the dialog, select the directory where the die base parts will be

PDW has the directory structure same as standard part library.

Step_4 Copy register file and data file from your base die base directory to your new template directory.

For example, copy the selected files and folders as left image, then rename universal_reg.xls to custom01_reg.xls


Open custom01_reg.xls and change path to new template path as above image.

Then open pdw_catalog.txt and edit the register line as above figure and save it.

Please check the model part name if it’s same under model folder.

Customization --- Insert Group Customization --- Insert Group

Insert Group customization is almost same as standard part customization, if you want to benefit from insert group automation, please follow the insert group directory structure and automation rule.

But we strongly suggest you use same method as standard part to handle your insert group.

Directory structure

Create a folder at same level as general folder and copy pdw_catalog.txt and insertgroup_reg.xls from general to the created folder, such as custom01 and modify the path in them.

The insert group automation includes two processes: one is dimension automation and another is position automation. • Dimension Automation PDW will recognize some parameters from strip layout process features, these parameters are assigned process parameter names, so it needs some rules to map these names to insert group parameter names, PDW provide the rules in default file (PDW_DEFAULT.DEF, see section 5 “PDW DIEBASE & INSERTGROUP”), for example, about 90 degree bending, in default file, it’s following rule: PDW_BEND_R1: R''bend PDW_BEND_L: L''bend The left side is PDW process parameter name, they are fixed, the right side is insert group parameter name, you can change to your own, but this name must be same with the parameter in the data file, ($PDW\insertgroup\bending\metric\general\straight_bend\punch\down_type):

Insert Group Design Automation Rules



Secondly, PDW will get a face from strip layout process feature and give it an internal name (for example “PDW_BEND_DIE_ALIGN_OBJ_NAME”); this face will be mated with a face in insert, whose name is defined by the mapping rule: PDW_BEND_DIE_ALIGN_OBJ_NAME: MATE_STRIP_FACE So if you change the name in the rule, you must assign the same name to the face in insert group template part.

• Position AutomationFirstly, PDW use pre-defined mate conditions (mainly with Die Base) in data file (See “MATE_CONDITIONS” section).



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Advanced Training --- PDW NX 1.0.2 Plus. Agenda Day 1 Introduction Part Analysis & Intermediate...

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