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AutoForm Proprietary – Confidential
Planning & Bidding I
Base Training
AutoForm Proprietary – Confidential
2
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AutoForm Proprietary – Confidential
Exercise
Base Training
Planning & Bidding I
PB I – R8
AutoForm Proprietary – Confidential
4
Exercise: Sidemember - Transfer Press
• Definition of a symmetrical setup and a mirrored part
• Identification of issues on Formcheck page and application of suitable countermeasures
• Refinement of Tooling and Die Set settings
Objectives
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Exercise: Sidemember - Transfer Press
• Part Data: SIDEMEMBER.CATPart
Part Information and Required Data
3
1
 m
m
View from x
View from z
1
3
0
 m
m
459 mm
HC180B
1.50 mm
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Getting started
1. Import Part SIDEMEMBER.CATPart.
2. Select afterwards the reference side and 
3. Extract the surface. 
Import Part Geometry
Exercise Import
1
Reference 
Side
2
3
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The Automatic Tipping can be calculated by 
reference to selected surface patches. 
1. Select two surface patches as tipping 
reference and
2. Click on Automatic Tipping.
The Tip Angle has to be modified manually to 
allow a suitable drawing process.
3. Go to Tip Angle tab and
4. Rotate the part by 180 ° around current Y 
axis. 
Tipping the Part Data
Automatic Tipping
Exercise Tip
2
1
Reference 
Patches
3
4
Rotation 
Amount
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1. Click on Half Input, Double Attached, 
Symmetrical to define a symmetrical setup
2. Open the Symmetry Plane Editor and 
3. Decrease Offset to Symmetry Plane.
Create a Mirrored Part
Use a Symmetry Plane
Exercise Import
1
2
3
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Due to the new setup a new center of die has to 
be defined. 
1. Click on Modify Center of Die.
Tipping the Part Data
Center of Die Definition
Exercise Tip
Center of 
Die
1
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1. Select a HC180B material from the 
AutoForm material database. The thickness 
is defined automatically from the solid 
import geometry. 
Define Blank Material
Assign Material
Exercise Material
1
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To separate drawing areas from secondary 
forming areas it might be necessary to trim 
surface patches. It will simplify the definition of 
forming areas. 
1. Add a Trim module.
2. Add a trim curve and separate the flange. 
Apply the modification afterwards.
Part Preparation
Adding a Trim Curve
Exercise Modify
Detail
Detail view: added trim curve
1
1
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Before calculating the Formcheck analysis the 
part has to be prepared. Areas for secondary 
forming operations should be defined to 
exclude them from the analysis. 
1. Click on Draw Parts.
2. Select all flanges and patches of extruded 
holes.
3. Add these patches to Secondary Forming 
register. 
4. Generate a Boundary Fill with 200 mm Roll 
Radius. 
5. Generate a Double Fill and apply the 
generation. Edit the double fill afterwards. 
Note: Double fill modifications are accessible via 
context menu or double click on corresponding 
spines. 
Formability Analysis
Exercise Formchk
Indication of Critical Part Areas
1
2
3
4
5
Double Fill between the parts
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6. Generate a Binder and reduce the Draw-In 
Reserve. 
The Draw-In Reserve defines the amount of 
material that is assumed to stay on the binder 
surface after drawing and, as such, the 
estimated blank outline will be affected by this 
parameter. 
7. Generate an Addendum via Geometric
method and apply the generation. 
8. An error message occurs stating that 
Development fails at 1 flange (see next 
slide).
Formability Analysis
Exercise Formchk
Indication of Critical Part Areas
6
7
8
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The error message shows, that one extruded
hole could not be developed.
1. The reason for that is an embossed radius
which is designed into the CAD-surface. An 
offset of 1.5mm is not possible for a radius
of 1mm.
2. The development will not be further
considered for Formcheck. When defining
the process plan, the radius embossment
has to be considered.
3. Go to the Develop Part tab and start the
Formcheck analysis.
4. Increase the Outer Holding Condition to 0.2. 
This is a meaningful compromise between
sufficient strain and little potential splits.
Formability Analysis
Exercise Formchk
Indication of Critical Part Areas
3
4
1
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Basically there exists a critical part area, that 
shows a risk of splits even for a minor outer 
holding condition (0.2). 
The production of the part will not be feasible, 
so that the critical area has to be modified 
before developing the process in detail. For a 
first estimation of countermeasures and their 
effect the tools of the modify page are helpful. 
Formability Analysis
Exercise Formchk
Indication of Critical Part Areas
Detail
Detail : Critical part area
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Formability Analysis
As a first optimization step, a segmentation of
the Outer Holding Condition will be performed
to avoid potential splits.
• Segmentation with Variable Holding 
Condition
• Realistic representation of outer holding
in an early phase.
• Approximation of minimal blank size with
an adjusted Outer Holding Condition 
value of 0.2 for the segmented holding
condition.
• Calculated forces of the Variable Holding 
Condition will be passed on to Plan-Stage.
1. Define proper segments in order to
decrease potential splits.
Segmentation of Outer Holding Condition
Exercise Formchk
1
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Formability Analysis
1. Define the Segment 2 with Holding 
Condition „Free“.
2. Click Apply to recalculate the formability
result.
Using Variable Holding Conditions leads to a 
slight improvement in regards of potential 
splits.
To eliminate potential splits completely, a 
Preform will be added. This Preform will be used
for the drawing operation while the final 
geometry will be formed in a following forming
operation.
Segmentation of Outer Holding Condition
Exercise Formchk
1
before after
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To smoothen the identified critical area, a 
Preform will be added.
1. Add a Preform.
2. Click on Input and selectsurface patches
according to the picture on the right.
3. Assign those by clicking on In.
4. Since the curve is located on the lower
radius, click on Swap.
5. Move the control points in the straight area
of the radius.
Part modification
Adding a Preform
Exercise Modify
1
2
5
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1. Change the Part Radius and Height Radius
to 2.5mm which fits to the existing part
radius.
2. Reduce theWall Radius to 4mm.
3. Set the Total Width to Min Width.
4. Confirm your inputs by clicking on Apply.
Part modification
Adding a Preform
Exercise Modify
1
2
3
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1. Repeat the Formcheck analysis including the 
part modification and check the results. If 
the results are not sufficient, edit the 
Preform and start a new analysis. 
The determined part modification can be 
directly taken as recommendation for the 
customer.
Formability Analysis
Exercise Formchk
Validation of Part Modification
Detail : Improved critical part area
Detail
1
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In this exercise a predefined press will be used. 
1. Click on Create Plan with Custom Press. 
Open Transfer Press 11000kN.zip from 
training directory. 
2. Check the Basic Properties in the Press 
Preview. Consider parameters like Bed 
Length or Ram Tonnage when defining the 
process plan. 
Plan Stage
Create Plan
Exercise 
1
Production
2
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3. Check the detected features on Plan page. 
Some features are missing. In addition, 
there are not enough operations for the 
amount of features.
4. Go back to Production page and add a Form 
Trim operation.
Plan Stage
Create Plan
Exercise PlanProduction
3
4
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1. Get an overview of the detected features 
and their assignment to the operations. The 
automatically created plan will be modified 
in the next steps. 
2. Edit the Trim Plan. The option is accessible 
via context menu. 
Process Plan
Feature Assignment
Exercise Plan
2
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3. Define trim segments. The part separation 
is assigned to the last operation.
4. Assign hole piercing to F-50. 
Process Plan
Feature Assignment
Exercise Plan
3 4
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5. Assign flanging features to F-60.
6. Assign extruded holes to F-60. 
Process Plan
Feature Assignment
Exercise Plan
5 6
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7. Add the missing flange as new feature and 
assign it to F-60.
8. The radius embossment (see result from 
Formcheck) is represented by a second 
Processing Unit.
9. Add a second PU “Extruding Up” to F-60.
10. The Preform also has to be formed to match 
the imported CAD geometry.
11. Add a Form Region and assign it to F-70.
Process Plan
Feature Assignment
Exercise Plan
7
9
11
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1. To smoothen the process plan, add another
Form / Trim operation.
2. Subsequently, evenly distribute the
Processing Units.
3. The final process plan is shown on the right.
Process Plan
Process Plan
Exercise Plan
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Sharing Die Sets means that certain components 
(Die Set Components) are shared between the 
affected operations. The consequence is that 
the amount and the size of those components 
are not derived from the size of the operation 
any more but from the total size of all 
operations that participate in the sharing.
A click between two operations activates die set 
sharing. 
1. Share the die set of T-30, T-40 and F-50.
2. Share the die set of F-60, F-70 and F-80.
Advanced Settings
Shared Die Sets
Exercise Production
1 2
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1. Select D-20 and
2. Edit Tooling Settings.
3. Set Height to 600 mm.
4. Apply Tooling Size afterwards to adopt 
height modification to other operations.
Advanced Settings
Modification of Tooling Settings
Exercise Production
1
2
4
3
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1. Select B-10 and
2. Edit Die Set Settings.
3. Set Height to 600 mm.
4. Edit the die set height also for the two 
remaining die sets. 
Advanced Settings
Modification of Die Set Settings
Exercise Production
3
1
2
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1. Click on Create Flat Blank.
2. Choose Copy From… and select the Blank 
Outline from the Formcheck. 
3. The defined blank represents the minimal 
shaped blank. It will further be embedded
in a ruled geometry.
Blank
Blank Definition
Exercise Outline
1
2
Generated Blank Outline
3
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1. Click on Nesting and Embedding to embed
the shaped blank in a minimal rectangular
blank.
2. Add a variant Embed: Rectangle: Stepped.
3. Since the utilization is nearly identical, the
variant Embed: Rectangle will be used for
further planning.
Blank
Blank Definition
Exercise Embed/Nest
1
2
Embedded Blank Outline
3
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1. Add Tooling.
2. Add Piece Cost.
Each category contains a set of input values and 
a set of cost result values specific for that 
particular category. Input values are either 
taken from other modules or categories within 
the Piece Cost. Others are just default values 
that can be adapted manually or within the 
Piece Cost standard.
The categories will be introduced in the 
following slides. 
3. Export calculated piece cost to a CSV file. 
Tooling Cost and Piece Cost
Calculation
Exercise Tooling Piece Cost
1 2
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Piece Cost
Tool and Maintenance Cost (1)
• Part Material: Informational value set within 
Part / Material page regarding the material 
type. 
• Tooling Cost: Total cost of the dies 
(Engineering, CNC machining, Die making, 
Die try-out and the Tool material costs). 
When the tooling costs are available on Plan 
/ Tooling, Total Tooling Cost value is taken 
automatically into Piece Cost, otherwise -
manual input is necessary. 
• Maintenance Parameters: maximum possible 
number of strokes before necessary tool 
maintenance and percentage of the total 
tooling cost and defines the cost of one 
maintenance cycle (new gas springs, re-
coating, die cleaning…).
Input Values
Essentials Piece Cost
1
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Piece Cost
Blank Material Cost (2)
• Utilization Factor presents the percentage of 
coil material that is used solely for the part 
production. This value is taken from the 
Blank stage; if no blank is available, default 
value of 70 % is set.
• Coil Weight per Blank is estimated coil 
weight necessary for one blank. It is 
calculated based on the part weight and 
given Utilization Factor. 
Input Values
Essentials Piece Cost
2
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Piece Cost
Production Line Cost (3)
• Press Hourly Cost is derived from the loaded 
press. 
• Press and Operation Downtime represents 
the percentage of downtime for press line 
service and maintenance
• Used Stroke Rate is set in respect to Press 
Min and Max stroke rate
• Strokes per Run has the default value of 
5000. The default value can be changed 
directly in the GUI or within Process Plan 
Standard. 
• Forming Issues Downtime per Run is the 
estimated downtime due the forming issues 
during one run.
Input Values
Essentials Piece Cost
3
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Piece Cost
Rework Cost (4)
• Rework Cost per Part describes the cost for 
the necessary rework process(es) for one 
part. 
• Quality Rework Rate represents the 
percentage of parts of the Total Production 
Volume that needs to be reworked. The 
default value depends on the Robustness 
Level : an increasing Robustness Level leads 
to a decreasing rework rate. 
Input Values
Essentials Piece Cost
4
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Piece Cost
Shipping Cost (5)
• Fixed Cost per Batch describes shipping cost 
that occurs for each batch of produced parts. 
• Variable Cost per Tonne contains the 
shipping cost for each tonne of produced 
parts. 
• Strokes per Batch represents the number of 
strokes that are "shipped" within one batch. 
Note that with one stroke there could be 
more than one part exiting the production 
line and therefore the number of strokes per 
batch can be smaller than the number of 
parts per batch. 
• Part Weight is calculated based on the part 
area and the material density. Taken from 
Part / Formcheck or Blank stages if available 
(considering thinning in these cases). 
Input Values
Essentials Piece Cost
5
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1. Go to Forces tab and
2. Calculate Approximate Form Forces per 
Operation.
Besides the forces per operation also the total 
force is calculated. The initially selected press 
(11000 kN) is oversized. 
Forces
Calculation
Exercise Plan
1
2
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1. Drag the Custom Press icon and drop it onto 
the existing production line to replace the 
initially selected press.
2. Select the Transfer Press 6300 kN. It has 
sufficient ram tonnage. 
Production Line Modification
Press Replacement
Exercise Production
1
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3. Go to Operation tab and 
4. Check the warning messages. 
An overlap was detected. Therefore the pitch or 
the tool length has to be modified. Consider 
also the bed length when modifying these 
values. 
5. Go back to Production Line tab and
6. Increase the Pitch to 500mm. 
Production Line Modification
Press Replacement
Exercise Production
3
6
5
4
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Check, if the new pitch corresponds to tool size 
and die set length. 
7. Set Tooling Length to 500 mm. Apply it also 
to other tools. 
8. Set the Die Set Length to 1500 mm.
Production Line Modification
Press Replacement
Exercise Production
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1. Check the new calculated piece cost. Due to 
a reduction of the Production Line cost the 
total cost per piece is dropped. 
Piece Cost
Calculation
Exercise Piece Cost
1
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Exercise: Sidemember - Transfer Press
• Using a symmetry plane to create a mirrored setup
• Improving Formcheck results via details on modify page
• Defining a detailed process plan setup
• Calculation of costs considering advanced settings
• Replacement of a press
Objectives Achieved
AutoForm Proprietary – Confidential
© 2019 AutoForm Engineering GmbH, Switzerland.
"AutoForm" and other trademarks listed under www.autoform.com or trade 
names contained in this documentation or the Software are trademarks or 
registered trademarks of AutoForm Engineering GmbH. Third party 
trademarks, trade names, product names and logos may be the trademarks or 
registered trademarks of their respective owners. AutoForm Engineering 
GmbH owns and practices various patents and patent applications that are 
listed on its website www.autoform.com. Software and specifications may be 
subject to change without notice.
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