Advanced Training
--- PDW NX 1.0.2 Plus
Agenda
 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
Feature Recognition [SMFR]
Project Initialization
Design Setting
Feature Pre-Process
Remove Unwanted Part
PDW NX 1.0.2 Plus
Blank Layout
Patch Hole
Scrap Design
• not an official release
Extend Sheet
Strip Layout
• no official CD produced
Clearance Management
• download from E-VIS
UG Basic Curves
• big difference --- break
through part & feature type
limitation (straight brake,
free-form, feature-based,
dumb body)
UG Sketch
Force Calculation
Die Base Design
Insert Group Design
Standard Part Management
Relief Design
Pocket Creation
BOM
Assembly Drawing
View Manager
Design Tools
Trim Part
UG Extract Curves
UG Patch Body
UG Unbend/Rebend
UG Form/Unform
UG MetaForm
Introduction --- Streamlined Design Process
Sheet Part Design Metal
PDW Progressive Die Design
SMD FeatureBased Model
SMFR
SMD & Modeling
Build Progressive Die Design Assembly
Set Major Design Parameters
Dumb Body
Product Feature  Process
Unfold  Blank
Layout Blank
How to Cut-off Scrap
Strip Layout
Simulate Virtual Manufactured Product
Predict & Balance Force
• Any CAD System [2D, 3D]
Design Die Base
• Any Industry
BOM
Assembly Drawing
CAM
Design Insert Group & Set Clearance
Design Standard Part & Set Clearance
Component Detailing
Design Relief for Formed Feature
Hole Data
Generate Pocket
Hole
Making
Wire EDM
…
Introduction --- PDW Design Assembly Structure & Relation
Feature Preprocess
Solid body
Faces of process
Blank Layout
Scrap Design
Sheet body
Die Base
Insert Group
Sheet body
Standard Part
Strip Layout
Strip Layout Simulation
Introduction --- PDW Design Change
Product
Exterior boundary Change
Add/remove feature
Pre-Process
Hole dimension change
Update Blank
Define new process
Blank Layout
Adjust blank layout: width, pitch, etc.
Scrap Design
Adjust scraps: remove,
Strip Layout
Insert Group
Process Definition
Delete unused inserts,
Pitch
add new inserts
Blank Orientation
Scrap Design
Sheet Metal Part
Remove All
add scraps
Part Analysis & Intermediate Status Preparation
Best Practice
Unform 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
Part Analysis & Intermediate Status Preparation
Case Study
UG NX2.0
Part Analysis & Intermediate Status Preparation
Case 1 (u_R_coin_coin.prt)

1 solid
body

Part Analysis & Intermediate Status Preparation
Case 2 (J_15428284.prt)

7 solid
bodies –
Unite

Part Analysis & Intermediate Status Preparation
Case 3
(U_form_bridge_emboss.prt)

Part Analysis & Intermediate Status Preparation
Case 3
Part Analysis & Intermediate Status Preparation
Case 3
3 solid
bodies
Unite
them
Note: also need check if unite will affect
part Unform/Form
Part Analysis & Intermediate Status Preparation
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.
Can not
automatically
get correct Blank,
Part Analysis & Intermediate Status Preparation
Case 5 (gh_form_b.prt)
•Create Part
Simplify
Wave-link free-form
feature solid body
Divide bend faces
for pre-bend
Add SM CUTOUT manually
(distance tolerance=0.001)
SMFR
Part Analysis & Intermediate Status Preparation
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
Part Analysis & Intermediate Status Preparation
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
Part Analysis & Intermediate Status Preparation
Case6 (demo_part02.prt)
• Create Intermediate States of Part
• Create Blank Part --- demo_part02_blk.prt
UG NX2.0
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
Unbend
Unbend
face name:
UP_DATUM_FACE
Process Design
Case 1
User Defined Process
(Interactive Layout)
Process Design
Case 2
User Defined Process
(Interactive Layout)
Process Design
Case 3
Process Design
Case 3
Remove additional
sheet bodies
User Defined Process
(Interactive Layout)
Process Design
Case 4
1.
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
Process Design
Case 4
User Defined Process
(Interactive Layout)
UG/Patch fail
Manually Refine it – Trim additional portion
Process Design
Case 5
1.
Project Initialization
2.
Create Blank in Feature Pre-Process
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)
5.
Delete the solid created automatically
Blank Layout
Scrap Design
Process Design
Case 5
UDS (user defined scrap)
Join Face
Extract Edges
(work part -*_nest_*)
Process Design
Case 5
Sketch
UDS
Scrap
In order to make sure the
sketch is same as the blank
boundary. Only turn on
Coincident
•
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
Process Design
Case 5
Strip Layout & Simulation
User Defined Process
(Interactive Layout)
Refine it
Process Design
Case 6
UG NX2.0
1.
Project Initialization
2.
Create Blank in Feature Pre-Process
Module
Blank Layout
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)
5.
Delete the solid created automatically
Scrap Design
Process Design
Case 6
Strip Layout & Simulation
User Defined Process
(Interactive Layout)
Process Design
Case 6
Strip Layout & Simulation
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
Structure Design --- Die Base
Case 5
Structure Design --- Die Base
Case 6
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.
Structure Design --- Insert Group
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 Die
Piercing Punch
Cavity Hole
Slug Hole Solid in
Bottom Backing Plate
& Die Shoe
Structure Design --- Insert Group
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)
Structure Design --- Insert Group
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
Structure Design --- Insert Group
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
Structure Design --- Insert Group
Case 5
• Free-Form Insert
Punch Head
Die Head
Refined Die Insert (add a
foot-proof)
Structure Design --- Insert Group
Case 6
• Insert Groups
Structure Design --- Insert Group
Case 6
• Insert Groups
Structure Design --- Standard Part
English Catalogs:
• Danly
• Dayton
• Hyson
• Superior
Metric
• Misumi
• Strack
• Dayton
• Hyson
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 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
Customization --- Standard Part
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
Customization --- Standard Part
Component Body (set partially shaded)
Create reference set named “TRUE” and add the
component bodies into this reference set
Pocket Cutting Body (yellow color, dashed line font)
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
Customization --- Standard Part
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
Customization --- Standard Part
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
Customization --- Standard Part
Step_04 Register Part
• Create a spreadsheet register file file, such as custom01_std_reg.xls/xs4 under
custom01
• Create pdw_catalog.txt file under custom01
Customization -- 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.
Customization -- Die Base
• 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.
Customization -- Die Base
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
Then open pdw_catalog.txt and edit the register line as above figure and save it.
Open custom01_reg.xls and change path to new template path as above image.
Please check the model part name if it’s same under model folder.
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.
Customization --- Insert Group
Insert Group Design Automation Rules
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):
Customization --- Insert Group
• Position Automation
Firstly, PDW use pre-defined mate conditions (mainly with Die Base) in data file (See “MATE_CONDITIONS”
section).
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.
Customization --- Insert Group
Customization --- Insert Group