Course catalog

About this Course:
Get introduced to acoustics and how you can perform acoustic simulations with Actran. This course will cover the following topics:

• Introduction to Actran and Acoustics
• Actran Overview
• Introduction to Acoustics
• Actran General Organization
• Acoustic Simulation.

Pre-Requisites
NA

About this Course:
Get introduced to acoustic radiation and treatment of powertrain components topics with Actran. This course will cover the following topics:

• The BC mesh Boundary Condition
• An Introduction to Acoustic Treatment
• An Introduction to the Actran Graphical User Interface (meshing, analysis handling, post-processing) and HPC.

Pre-Requisites
Introduction to Actran and Acoustics

About this Course:
Learn how you can perform vibroacoustic simulations with Actran. This course will cover the following topics:

• The Transmission Loss setup in Actran
• An Introduction to Acoustic Treatment
• An Introduction to the Actran Graphical User Interface (meshing, analysis handling, post-processing) and HPC.

Pre-Requisites
Introduction to Actran and Acoustics

About this Course:
Get introduced to acoustic propagation in ducts and how you can model acoustic duct modes with Actran. This course will cover the following topics:

• Acoustic Radiation and Duct Propagation
• Dissipation in Perforated Plates
• An Introduction to the Actran Graphical User Interface (meshing, analysis handling, post-processing) and HPC

All topics are accompanied by their respective exercises.

Pre-Requisites
Introduction to Actran and Acoustics

About this Course:
Get introduced to aeroacoustics topics with Actran. This course will cover the following topics:

• An Introduction to Aero-acoustics with Actran
• Aero-acoustic Guidelines and Signal Processing
• An Introduction to the Actran Graphical User Interface (meshing, analysis handling, post-processing) and HPC

All topics are accompanied by their respective exercises.

Pre-Requisites
Introduction to Actran and Acoustics

40 hours - Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
Beginner: This course provides a foundation of skills needed to begin using Adams' powerful virtual prototyping, testing and visualization capabilities.

16 hours – Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
Beginner: This course provides a basic understanding of Adams Solver and Adams View. This course is a pre-requisite for Adams Car (ADM740) and/or Adams Chassis (ADM761) training classes. Presented in this class are all of the basics of building models in Adams View (PARTs, JOINTs, MOTIONs, forces, function expressions, simulation types), running simulations with Adams Solver and simple plotting with Adams PostProcessor. Users who intend to do moderate model creation/optimization in either Adams View or Adams Car Template Builder are strongly encouraged to take the ADM701 Complete Multibody Dynamics Analysis with Adams class instead of this one.

 

8 hours – Online Self-Paced Course
Course Materials, Workshops and Model Files

About this Course:

Advanced: This class is intended for moderately experienced Adams users wanting to expand their knowledge of advanced modeling elements and techniques in Adams Solver. Advanced modeling elements are entities such as the discrete flex link in Adams View, the general constraint (GCON) and the differential equation (DIFF) elements. The use of these elements with scripting & function expression logic, new SENSOR functionality and advanced function expressions in Adams Solver will be discussed.

16 hours – Online Self-Paced Course
Course Materials, Workshops and Model Files

About this Course:
Intermediate: This course provides knowledge of Adams Solver theory with an emphasis on tying theoretical concepts back to Adams Solver solutions settings (ERROR, HMAC, SI2, MAXIT, etc.). Strategies for creating robust models and sensible solution control settings are a focus. The various phases of solution (statics, kinematics, dynamics) are covered in detail and best practices for each are identified.

8 hours – Online Self-Paced Course

Course Materials, Workshops and Model Files

About this Course:

Advanced: This course teaches how to create Adams Solver user subroutines. Initial setup with pre-existing libraries is considered, followed by the types of Adams Solver elements, which can be over-ridden. Dealing with user input is considered along with usage of the many built-in utility subroutines. Querying Adams Solver for system state information (displacements, velocities, forces, etc.) is covered in detail, followed by initialization (FLAG) and differencing (DFLAG) considerations.

16 hours - Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
Beginner: This course teaches how to parameterize a model in order to determine how different modeling parameters influence the design and how to iterate on those to achieve the optimal design using Design Studies, Design of Experiments (DOE) and Optimization capabilities in Adams View.

16 hours - Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
Beginner: This course teaches how to automate tasks in Adams View for efficiency. The Adams View Command Language is studied in detail along with looping, macros and the creation of custom menus and dialog boxes.

Online Self-Paced Course
Course Materials, Workshops with Model Files

This class is both an introduction to the Python programming language and the Adams Python interface API. The Python introduction section has comprehensive background and examples on:

• Basic types, lists, dictionaries
• List comprehensions, filtering & sorting.
• Logic, flow control & looping
• Functions, automatic documentation
• Object oriented methods using class structures
• File handling, string processing & efficient search

The Adams Python-specific content includes:

• The class structure in Adams
• Getting object references, setting properties
• Creating new elements, iterating through existing collections
• Examples of cmd script translations.

 

Online Self-Paced Course
Course Materials, Workshops with Model Files

Topics Covered:

• The Workbook Format
• Submitting and Handling Jobs
• Working with the Web Server and Job Server
• Functionality for Adams Analyst and Adams Experts

 

24 hours - Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
Beginner: This course teaches how to use Adams Flex to incorporate flexibility into your Adams models and is primarily focused on using component modal synthesis via the Modal Neutral File (MNF) and Adams View.

 

16 hours - Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
Beginner: This course teaches how to connect your Adams model to control systems developed in MATLAB or Easy5. Techniques for combining linear, nonlinear, continuous and sampled control systems with your Adams model are presented, along with tutorials. Converting your MATLAB or Easy5 model into a native Adams entity via Control System Import to run the combined model completely within Adams will also be discussed. Other topics presented include an overview of all System Elements, including State Variables, Differential Equations, Linear State Equations, and General State Equations to develop models (e.g. control systems) supplemental to your mechanical model.

8 hours – Online Self-Paced Course
Course Materials, Workshops and Model Files

About this Course:
Beginner: This course teaches how to perform frequency-domain analysis. Using Adams Vibration, you can study forced vibrations within the Adams model at isolated instances. The results from Adams Vibration can be used in noise/vibration/harshness (NVH) studies.

8 hours - Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
Intermediate: This course teaches how to create factors and responses in your model, understand how Design Variable range settings work, create complex response definitions in Adams, understand DOE Screening/Response Surface Strategies, become comfortable with DOE output statistics, create Monte Carlo variation studies and effectively create and run large design variation studies.

32 hours - Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
Beginner to Intermediate: This course provides a comprehensive overview of Adams Car that ranges from the basics of subsystem adjustment through to progressively more advanced topics such as event creation, template creation, tire selection, control system integration, flexible body swapping and much more.

8 hours – Online Self-Paced Course
Course Materials, Workshops and Model Files

About this Course:
Beginner: This course teaches how to create assemblies of suspensions and full vehicles, including driveline components, and then analyze them to understand their performance and behavior. Presented in the class are all the basics of building models in Adams Driveline (engine, gearbox, prop shafts and differentials), running simulations and simple plotting with Adams PostProcessor.

16 hours – Online Self-Paced Course
Course Materials, Workshops and Model Files

Topics Covered:

• Introduction and Overview
• Tire Modeling Important Aspects
• Tire Testrig and contact Models
• Road Model Comparison and Road Builder
• Tire Model Parameters

 

8 hours - Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
Beginner: This course teaches Adams Car for Formula SAE (FSAE) competition students. Students will learn how to customize the FSAE database example and analyze vehicle kinematics and dynamics with Adams Car.

Course Overview: The Adams Car Driving Machine is used to perform full-vehicle analyses. The Driving Machine drives your virtual vehicle according to your instructions much like a test driver would drive an actual vehicle.

This class is a comprehensive overview of Adams Car driver that ranges from the basics of driving machine to progressively more advanced topics such as steering controls, gear -clutch, throttle-brake controls, smartdriver and much more.

Pre- Requisites: ADM740 - Adams Car

Topics covered:

• Fundamentals of driving machine
• Open loop Control
• Closed Loop machine control
• Adams Smartdriver

Course Description: Using Adams Car and Easy5 to model electric vehicle motor & powertrain configurations. Incorporating electric motor models into the vehicle model using the Functional Mockup Interface (FMI) standard. Merging Driver Assist System (DAS) models into an existing Adams Car model.

Pre-requisites (if any): ADM740 (Adams Car), ADM711 (Adams Controls)

Topics Covered:

• Adams Car templates for managing different eMotor configurations (FWD, RWD, AWD)
• eMotor creation using spline-based methods
• eMotor creation using detailed FMU models from other packages (Matlab, Easy5, MapleSim, etc)
• Regenerative braking implementation in Adams Car
• Driver Assist System (DAS) integration using the FMI standard (Torque Vectoring model created in Easy5)

Version: 2021.0.1 or higher

8 hours - Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
Beginner: This course teaches how to build detailed models containing belts, chains or gears with Adams Machinery.

8 hours – Online Self-Paced Course
Course Materials, Workshops and Model Files

About this Course:
Beginner: This course teaches how to perform Basic Suspension and Full Vehicle Analysis using Adams Chassis.

Online Self-Paced Course
Course Materials, Workshops with Model Files

Topics Covered:

• Welcome to Adams Tracked Vehicle Training
• Introducing Adams Tracked Vehicle
• Basic Concepts
• Creating and Adjusting Subsystems
• Creating and Simulating Suspensions
• Creating and Simulating Full Vehicles
• Track System Setup
• String Track
• Soft Soil
• Building Templates
• Adams Tracked Vehicle Components
• Communicators
• Importing CAD Geometry
• Using Flexible Bodies
• Exploring Templates

About this Course:
This course gives a general overview of the main capabilities and workflows of Adams Modeler. It covers, the user interface, model creation, simulation, results review, integration with the Adams View interface mode and creation of linear flexible bodies.

Pre- Requisites
ADM701 (Complete Multibody Dynamics Analysis with Adams) and ADM710 (Flex Body Dynamics and Model Stress Recovery using Adams)

Topics covered

• Adams Modeler Interface,
• CAD Body Editing,
• Joints, Motions, Function Expressions,
• Contacts and Generative Behavior,
• Flexible Body Import
• Flexible Body Generation

16 hours - Online Self-Paced Course
Course Materials, Workshops and Model Files

About this Course:
This course will give you the foundation of skills you'll need to use Adams' plugin Gear AT. This base course explains the theory behind the plugin, advantages, difference and consistency to classical approaches. Also, you are guided through the first steps of practical usage of Gear AT.

Topics Covered:

• Short summary of available approaches to simulate/calculate gears
• Description of the technology/workflow to simulate gears in Gear AT
• Step-by-step tutorial how to create correct gear shapes
• Step-by-step tutorial how to create Gear AT gears for Adams
• Step-by-step tutorial how to set up gear meshing behavior
• Description of the available methods to apply topology modifications and manufacturing errors
• Step-by-step tutorial how to define and apply shape modifications
• Introduction, how to evaluate gear specific results

Online Self-Paced Course
Course Materials, Workshops with Model Files

The objective of the Digimat Introductory Training is to give a first view of the Digimat products to a new customer or prospect. The content of this training focuses on the workflow and the hands-on exercises. The theoretical aspects of Digimat's capabilities are not presented.

Topics:

• Digimat-MF & Digimat-MX – Definition and calibration of a Digimat material
• Digimat-RP – Use of a Digimat material in Marc structural analysis. Capture the anisotropic and non-linear behavior of the material.

 

Online Self-Paced Course
Course Materials, Workshops with Model Files

Key to the success of your structural application is to take into account the effect of the manufacturing process that drives the local microstructure in the composite component. Because composite materials exhibit a highly anisotropic behaviour, the local microstructure will contribute to the composite material and final component performances. This course will enable you to implement a complete solution to be able to optimize and validate the structural design of your part, assess its feasibility and evaluate its performances, including stiffness and failure among others. The methodology is developed with a specific focus on the best practices of the software usage and a comprehensive understanding of the results.

In this training, the following suite of Digimat modules will be covered:

• Digimat-MF is used to understand and create a Digimat material model. A Digimat material model is predictive for any microstructure and loading condition.
• Digimat-MX enables to reverse-engineer a Digimat material model from experimental data. The Digimat material database contains an extensive set of Digimat material models provided by different material suppliers and can further be extended with your data.
• Digimat-MAP is used to transfer manufacturing data from a processing mesh to the structural mesh of your application.
• Digimat-RP provides an easy, complete and comprehensive solution to couple manufacturing data and Digimat material models with the CAE code of your choice. A fiber orientation estimator integrated within the solution will also be presented.

 

Online Self-Paced Course
Course Materials, Workshops with Model Files

Many of the arising new technologies are owed to the development of new composite materials. The material properties determine the performances that can be achieved. The in-depth and thorough understanding of materials at the microscopic scale is therefore required to predict the performances at the macroscopic scale. In this course, you will gain insight into materials and investigate the microscopic mechanisms that dominate the macroscopic properties. You will virtually evaluate the performance of new composite materials to be able to identify promising candidates providing the targeted features. The training will also consider tips and recommendations for the calibration of new composite materials.

In this training, the following suite of Digimat modules will be covered:

• Digimat-MF relies on the mean field homogenization to combine the per-phase properties of the composite constituents with microstructural information to generate a model-based representative volume element.
• Digimat-MX will assist you in the procedure to determine the constituents’ parameters that enable to predict the composite performances.
• Digimat-FE considers a finite element analysis of a realistic representative volume element to gain an in-depth view into composites by direct investigation.
• Digimat-VA is used to generate virtual allowable and compute the behaviour of unnotched, open hole and filled hole coupons among others

 

Online Self-Paced Course
Course Materials, Workshops with Model Files
Applicable Software: scFLOW

The main objectives of this course are to enable attendees to become familiar with the operations of scFLOW. In this course, attendees will be able to learn the rough operations of scFLOW through the simple sample.

Course Outline:

1. Outline of Analysis in scFLOW
2. Create Input data
3. Execute Analysis
4. Check output results
5. About User Guides

Description

The main objectives of this course are to enable attendees to become familiar with the initial set-up of scFLOW. Attendees will also learn about available user resources including training.

Attendees will gain knowledge of:

• Initial set-up and software configuration
• Recommended training materials

Course Outline:

1. Initial settings and launching of scFLOW modules
2. Recommended training

Online Self-Paced Course
Course Materials, Workshops with Model Files
Applicable Software: scSTREAM

The objective of this course is to introduce the novice scSTREAM user to intermediate level details of the set-up, execution and analysis of a typical thermo-fluid simulation in building design. The hands-on example concerns thermal management of interior living spaces.

Recommended pre-requisite: scSTREAM 101 video

Attendees will gain knowledge of:

• Importing CAD data, material libraries and parts attributes
• Defining geometry, materials and attributes using scSTREAM tools
• Analysis settings for thermo-fluid simulation of living space
• Monitoring the simulation during execution
• Standard post-processing methods

Course Outline:

1. scSTREAM program structure and operational procedure
2. Intermediate example: Hospital room
• Importing data for geometry, materials and attributes
• Setting analysis conditions
• Mesh generation
• Solver execution and monitoring
• Intermediate post-processing
3. Contacting the Technical Support team
4. Additional Content
• Setting up the hospital case manually (no imports)

Online Self-Paced Course
Course Materials, Workshops with Model Files
Applicable Software: scSTREAM

The scSTREAM for Architecture - At a Glance webinar is designed to be the quickest way to learn about scSTREAM in the architecture industry!

This presentation will cover:

• Basics of CFD
• Examples of CFD in architecture
• Overview of scSTREAM
• Functions directly related to architecture and building

This presentation is intended to give the audience an overview of scSTREAM's functions and features. Specifically, this video is meant to inform architects and engineers in the architecture and building industry.

Online Self-Paced Course
Course Materials, Workshops with Model Files
Applicable Software: scSTREAM / HeatDesigner

The main objectives of this course are to enable attendees to become more familiar with the initial set-up and basic operation of scSTREAM used for electronics applications.

Attendees will gain knowledge of:

• Initial set-up and software configuration
• Software structure and standard files
• Using the scSTREAM interface
• Basic operational procedure
• Importing CAD data
• Generation of a simple mesh
• Basic post-processing methods
• Recommended training materials

Course Outline:

1. Initial settings and launching of scSTREAM modules
2. Recommended training
3. scSTREAM interface and program structure
4. Introductory example: Cell phone
• Importing geometry data
• Setting analysis conditions
• Mesh generation
• Solver execution
• Basic post-processing
5. Contacting the Technical Support team

Online Self-Paced Course
Course Materials, Workshops with Model Files
Applicable Software: scSTREAM

The main objectives of this course are to enable attendees to become familiar with the initial set-up and basic operation of scSTREAM. Attendees will also learn about available user resources including training.

Attendees will gain knowledge of:

• Initial set-up and software configuration
• Software structure and standard files
• Using the scSTREAM interface
• Basic operational procedure
• Generation of a simple mesh
• Basic post-processing methods
• Recommended training materials

Course Outline:

1. Initial settings and launching of scSTREAM modules
2. Recommended training
3. scSTREAM interface and program structure
4. Introductory example
• Creating a simple geometry
• Setting analysis conditions
• Mesh generation
• Solver execution
• Basic post-processing

Online Self-Paced Course
Course Materials, Workshops with Model Files

The objective of the Digimat Introductory Training is to give a first view of the Digimat products to a new customer or prospect. The content of this training focuses on the workflow and the hands-on exercises. The theoretical aspects of Digimat's capabilities are not presented.

Topics:

• Digimat-MF & Digimat-MX – Definition and calibration of a Digimat material
• Digimat-RP – Use of a Digimat material in Marc structural analysis. Capture the anisotropic and non-linear behavior of the material.

 

Online Self-Paced Course
Course Materials, Workshops with Model Files

Key to the success of your structural application is to take into account the effect of the manufacturing process that drives the local microstructure in the composite component. Because composite materials exhibit a highly anisotropic behaviour, the local microstructure will contribute to the composite material and final component performances. This course will enable you to implement a complete solution to be able to optimize and validate the structural design of your part, assess its feasibility and evaluate its performances, including stiffness and failure among others. The methodology is developed with a specific focus on the best practices of the software usage and a comprehensive understanding of the results.

In this training, the following suite of Digimat modules will be covered:

• Digimat-MF is used to understand and create a Digimat material model. A Digimat material model is predictive for any microstructure and loading condition.
• Digimat-MX enables to reverse-engineer a Digimat material model from experimental data. The Digimat material database contains an extensive set of Digimat material models provided by different material suppliers and can further be extended with your data.
• Digimat-MAP is used to transfer manufacturing data from a processing mesh to the structural mesh of your application.
• Digimat-RP provides an easy, complete and comprehensive solution to couple manufacturing data and Digimat material models with the CAE code of your choice. A fiber orientation estimator integrated within the solution will also be presented.

 

Online Self-Paced Course
Course Materials, Workshops with Model Files

Many of the arising new technologies are owed to the development of new composite materials. The material properties determine the performances that can be achieved. The in-depth and thorough understanding of materials at the microscopic scale is therefore required to predict the performances at the macroscopic scale. In this course, you will gain insight into materials and investigate the microscopic mechanisms that dominate the macroscopic properties. You will virtually evaluate the performance of new composite materials to be able to identify promising candidates providing the targeted features. The training will also consider tips and recommendations for the calibration of new composite materials.

In this training, the following suite of Digimat modules will be covered:

• Digimat-MF relies on the mean field homogenization to combine the per-phase properties of the composite constituents with microstructural information to generate a model-based representative volume element.
• Digimat-MX will assist you in the procedure to determine the constituents’ parameters that enable to predict the composite performances.
• Digimat-FE considers a finite element analysis of a realistic representative volume element to gain an in-depth view into composites by direct investigation.
• Digimat-VA is used to generate virtual allowable and compute the behaviour of unnotched, open hole and filled hole coupons among others

 

Course Overview: This course outlines the basic features and functionality of COSTOPTIMIZER® Professional.
Important COSTOPTIMIZER ® Professional also includes Process Planner, which enables you to configure a Line Die or Progressive Die Process.
See the PROCESS PLANNER Courses for more information.

Topic Covered:

1. Overview of COSTOPTIMIZER® Advanced and Material Library
2. Importing a geometry and defining material
3. Filling and removing holes and notches
4. Creating a double attached part
5. Generating a tool mesh and punch direction
6. Defining the forming process and applying forming constraints
7. Analysing Thickness Strain, Safety Zones, and Forming Limit Diagram
8. Defining and exporting a blank
9. Defining die plane and layout parameters
10. Selecting a progressive nesting layout
11. Solving for a mirror carrier layout
12. Editing the coil width of the nesting layout
13. Adding stretch webs to a mirror carrier layout
14. Setting sheet parameters for a strip nesting layout
15. Defining layout parameters for a strip nesting layout
16. Solving for a One Up strip nesting layout
17. Exporting layouts and generating workbench reports

Prerequisites: Download and install FormingSuite COSTOPTIMIZER Professional.

Locate the B Pillar.igs geometry file in the Geo Folder: C:FTIgeo2 up_brkt.igs"

Course Overview: This course outlines the basic features and functionality of FormingSuite Professional

Topic Covered:

1. Overview of FormingSuite Professional and Material Library
2. Importing a geometry and defining material
3. Filling and removing holes and notches
4. Creating a double attached part
5. Generating a tool mesh and punch direction
6. Defining the forming process and applying forming constraints
7. Defining an incremental layout parameters and solving
8. Analysing incremental results for formability
9. Performing a circle grid analysis
10. Analysing Thickness Strain, Safety Zones, and Forming Limit Diagram
11. Analysing Springback
12. Defining and exporting a blank
13. Defining die plane and layout parameters
14. Selecting a progressive nesting layout
15. Solving for a mirror carrier layout
16. Editing the coil width of the nesting layout
17. Adding stretch webs to a mirror carrier layout
18. Setting sheet parameters for a strip nesting layout
19. Defining layout parameters for a strip nesting layout
20. Solving for a One Up strip nesting layout
21. Exporting layouts and generating workbench reports

Prerequisites: Download and install FormingSuite Professional.
Locate the following geometry files in the Geo Folder: C:FTIgeo
- 2 up_brkt.igs
- box-cb-blank.igs
- box-cb-binder.igs
- box-cb-punch.igs
- box-cb-die.igs
- box-cb-pad.igs
- box-cb- Part 1.igs"

Course Overview: This course outlines the basic features and functionality of PROCESS PLANNER 2021. Specifically, it focusses on the Line Die Plan Workbench

Topic Covered:

1. Overview of PROCESS PLANNER – Line Die Plan
2. Defining Blanking Settings
3. Using the Editable Blanking Table to define blanking process
4. Configuring a Two Coil Workflow
5. Defining Part Features
6. Defining Line Die Plan Process and Press Coordinate System
7. Configuring the Die Lineup using the Line Die Plan Process Table
8. Generating and analysing the Summary Table
9. Creating a Line Die Plan workbench Report

Prerequisites: Download and install FormingSuite COSTOPTIMIZER Professional 2021.
Important Process Planner is only included as part of COSTOPTIMIZER Professional 2021. This course requires you to have completed the COSTOPTIMIZER Professional – Basic Introduction course.

Locate the Transfer.igs geometry file in the Geo Folder: C:FTIgeoTransfer.igs"

Course Overview: This course outlines the basic features and functionality of PROCESS PLANNER 2021. Specifically, it focusses on the Prog Die Process Workbench.

Topic Covered:

1. Overview of PROCESS PLANNER - Progressive Die Process
2. Defining Part Features
3. Defining Prog Die Process Settings
4. Using the 2D Process Table to define blanking process
5. Using the 3D Process Table to configure Progressive Die operations
6. Generating and analysing the Summary Table
7. Creating a Prog Die Process workbench report.

Prerequisites: Download and install FormingSuite COSTOPTIMIZER Professional.
Important Process Planner is only included as part of COSTOPTIMIZER Professional 2021. This course requires you to have completed the COSTOPTIMIZER Professional – Basic Introduction course.
Locate the 2 up_brkt.igs geometry file in the Geo Folder: C:FTIgeo2 up_brkt.igs"

2 Day Course

This course is to provide an understanding of stamping failures through analysis of metallurgical properties and behavior of steel during forming processes. It will provide a detailed review of the latest material grades (including advanced high strength and dual phase materials) and countermeasures for addressing stamping defects. A methodology for Successful Failure Analysis using metallurgical, die & part, and press perspectives will be presented. 

Course Outline:  

1.0 Overview of Failure Analysis  
1.1 Methodology for Successful Failure Analysis
1.2 Die and Part Investigatio
1.3 Press Investigation
1.4 Material Examination
1.5 Summary 

2.0 Analysis of Material Properties on Formability  
      2.1 Mechanisms of Elastic and Plastic Deformation  
      2.2 Stress, Strain and Mechanical Properties  
      2.3 Advanced Stamping Materials 
      2.4 Circle Grid Analysis and the Forming Limit Diagram 
      2.5 Effect of n-Value 
      2.6 Effect of r-Value  
      2.7 Strain Aging 
      2.8 Stages of Deformation and Mechanisms of Fracture 
      2.9 Die Surface Treatment 
      2.10 Summary  

3.0 Formability Analysis  
      3.1 Countermeasures for Die Related Issues 
      3.2 Countermeasures for Markings on a Part 
      3.3 Countermeasures for Forming Related Issues 
      3.4 Summary 
Group Exercise: Identify the Countermeasures for Stamping Failures  

4.0 Evaluation of a Failure Analysis  
      4.1 Background Information for a Failure Analysis 
      4.2 Review of Case Studies 
      4.3 Summary 
Group Exercise: Determine the Root Cause of a Failure Analysis  

1 Day Course

The objective of this course is to provide an understanding of the applications, benefits and guidelines for Advanced Stamping Materials. It will include Advanced High Strength Steels (AHSS), Dual Phase and Trip steels. Recommendations for part design with respect to issues related to die maintenance, manufacturing, and welding will be provided. 

Course Outline: 

1.0 Steel Making
1.1 The Composition of Steel Mass
1.2 Steel Making Overview
1.3 Raw Materials
1.4 Iron Making
1.5 Steel Making
1.6 Casting
1.7 Hot Rolling
1.8 Cold Rolling, Annealing, and Tempering
1.9 Galvanizing 

2.0 Material Properties  
2.1 Material Properties 
2.2 Factors of Material Properties 
2.3 Tensile Test
2.4 Stress-Strain Diagram
2.5 Deformation
2.6 Yield Strength
2.7 Tensile Strength
2.8 Elongation
2.9 N-Value
2.10 R-Value 
2.11 Anisotropy 
2.12 Mechanical vs. Material Properties

3.0 Formability Analysis 
3.1 Formability  
3.2 Factors of Formability  
3.3 Strain 
3.4 Circle Grid 
3.5 Strain Analysis
3.6 Applying the Circle Grid
3.7 Measuring Circle Grid
3.8 Measuring Surface Strain
3.9 Forming Diagram
3.10 Thinning Analysis
3.11 Skin Panel Strain Analysis
3.12 Argus Analysis 

4.0 Microstructure and Strengthening Mechanisms 
4.1 Conventional Steel 
4.2 Microstructure Basics 
4.3 Conventional Steel Microstructure 
4.4 Mild Steel
4.5 Solid Solution Strengthening
4.6 Work Hardening
4.7 Bake Hardening
4.8 Precipitation Hardening 

5.0 Advanced High Strength Steels
5.1 CAFÉ Trends
5.2 Material Trends 
5.3 Advanced High Strength Steel
5.4 Dual Phase Steel
5.5 Trip Steel
5.6 Complex Phase and Martensitic Steel
5.7 Emerging Advanced High Strength Steels
5.8 AHSS Mix Predictions 

6.0 AHSS Mix Predictions 
6.1 Strength vs Elongation 
6.2 Work Hardening at Low Strain 
6.3 Bake Hardening  
6.4 Fatigue Strength 
6.5 Case Study 1- Downgauge Opportunity  
6.6 Dent Resistance 
6.7 Stiffness
6.8 N-Value
6.9 Case Study- Material Optimization Opportunity
6.10 R-Value
6.11 TRIP Steel Draw-ability
6.12 Total Elongation & Bending
6.13 Local Elongation (a.k.a. Edge Cracking)
6.14 Case Study 3 Formability Comparison
6.15 Dual Phase Steel Forming Limit Diagram
6.16 Case Study 4 – Downgauge Opportunity 
6.17 TRIP and Martensitic Steel FLD  

7.0 Managing Dimensional Instability 
7.1 Springback and Dimensional Instability  
7.2 Part Design 
7.3 Process Design & Control 
7.4 Hot Forming

Who should attend?
Product, Design, Process, Manufacturing, Quality, Tooling Engineers and Tool & Die Makers

3-Day Course

The objective of this course is to understand the inputs into a stamping operation and how to interpret the results. The effects of parameters such as geometry, material properties, press curves, and binder & blank holder capabilities are thoroughly discussed. It teaches the fundamentals of analyzing a part by understanding its markings and how to evaluate its severity. 

Course Outline 

1.0 Understanding Material Properties 
1.2 How a Stamping Holds its Shape  
1.3 Effect of n and r-Values on Forming 
1.4 Typical, n, r and Yield Strength for Different Materials
2.0 Circle Grid and Thinning Strain Analysis 
2.1 Use of Circle Grid and Thinning Strain Analysis 
2.2 How to Apply Circle Grids
2.3 Determining and Plotting Major and Minor Strains
2.4 Concept of Forming Limit Diagram
2.5 Determining the Position of the Forming Limit Curve for Different Materials
2.6 Interpretation of Results
2.7 How to Perform Thinning Strain Analysis 
2.8 Benefits of Thinning Strain Analysis (TSA)
3.0 Overview of the Press
3.1 Press Terminology 
3.2 Type of Presses 
3.3 Countermeasures for Forming Related Issues 

4.0 Understanding Stamping Dies 
4.1 Terminology of a Stamping Die 
4.2 Types of Stamping Dies 
4.3 Die/Press Combination 

5.0 Understanding the Markings on a Component
5.1 Introduction 
5.2 Definition of Terms 
5.3 Movement of Punch and Die Impact Lines or Feature Lines 
5.4 Positioning of Drawbeads and Material Movement Through Them 
5.5 Understanding Scrap and Offal 
5.6 Die Factors That Can Effect Product Quality 
5.7 Group Exercise to Identify Markings 

6.0 Types of Defects
6.1 Introduction 
6.2 Splitting Defects 
6.3 Wrinkling Defects  
6.4 Defects Due to High and Lows 
6.5 Stiffness and Dent Resistance 
6.6 Group Exercise to Identify Defective Areas 

7.0 Measuring the Formability of Stampings 
7.1 Understanding the Evaluation of Complex Panels  
7.2 Formability Guidelines for Local Features 
7.3 Formability Guidelines for Regional Features 
7.4 Global Analysis of a Panel 
Who should attend?

Tooling Supervisors, Tooling and Quality Engineers, and Tool and Die Makers 

3 day course

The objective of this course is to understand the inputs into a stamping operation and how to interpret the results. The effects of part geometry, material properties, part defects, formability guidelines are thoroughly discussed. It teaches the fundamentals of analyzing a part by understanding its markings.

1.0 Understanding Material Properties
1.1 How a Stamping Holds its Shape
1.2 n -Value and Stretchability
1.3 r -Value and Drawability
1.4 Typical n, r and Yield Strength for Different Materials
1.5 Advanced Stamping Materials
1.6 Aluminum Alloys
1.5 Aluminum vs Steel Examples

2.0 Circle Grid and Thinning Strain Analysis
2.1 What is Circle Grid and Thinning Strain Analysis
2.2 Use of Circle Grid and Thinning Strain Analysis 
2.3 How to Apply Circle Grids
2.4 Determining and Plotting Major and Minor Strains
2.5 Concept of a Forming Limit Diagram
2.6 Determining the Position of the Forming Limit Curve for Different Materials
2.7 Interpretation of Results
2.8 How to Perform Thinning Strain Analysis
2.9 Benefits of Thinning Strain Analysis (TSA)

3.0 Hydroforming and Stretch Forming
3.1 Basic Principles of Tube Hydroforming
3.2 Sheet Hydroforming
3.3 Stretch Forming
3.4 Rubber Pad Forming

4.0 Manufacturing Considerations for Designers
4.1 Terminology of a Stamping Die
4.2 Aluminum Manufacturing Issues

5.0 Types of Defects
5.1 Introduction
5.2 Splits or Smiles
5.3 Wrinkling Defects
5.4 Defects Due to High and Lows
5.5 Stiffness and Dent Resistance

6.0 Modes of Forming and Guidelines
6.1 Cutting
6.2 Bending, Flanging and Hole Expansion
6.3 Stretching and Embossing
6.4 Drawing and Cup Drawing
6.5 Formability Guidelines for Regional Features

7.0 Measuring the Formability of Stampings
7.1 Understanding the Evaluation of Complex Panels
7.2 Formability Guidelines for Local Features
7.3 Formability Guidelines for Regional Features
7.4 Global Analysis of a Panel

1-Day Course

In this workshop you will learn how to perform and interpret circle grid and thinning strain analysis. Through exercises with actual parts you will be performing hands-on circle grid and thinning measurements. You will review the limitations and guidelines for the use of circle grid and thinning measurements. Also included is the measurement and application of surface stretch analysis for outer panels. 

Course Outline 

1.0 Overview of Thinning Strain and Circle Grid Analysis 
1.1 Understanding Thinning Strain and Circle Grid Analysis 
1.2 Applications of Thinning Strain and Circle Grid Analysis  
1.3 What is the Difference Between Thinning Strain Analysis and Circle Grid Analysis  
1.4 Procedure for Thinning Strain and Circle Grid Analysis 
1.5 Other Uses for Thinning Strain and Circle Grid Analysis 

2.0 Fundamental of Thinning Strain Analysis (TSA)

2.1 Establishing the Thinning Limit
2.2 Thinning Strain
2.3 Calculating Thinning Strain
Exercise: Calculate Thinning Strain 
2.4 Measuring Thickness
2.5 Finding ‘Hot Spots’
2.6 Highlighting Areas for Circle Grid Analysis

3.0 Fundamental of Circle Grid Analysis
3.1 Types of Circle Grids
3.2 Methods for Applying Circle Grids
3.3 Major Strain and Minor Strain
Exercise: Calculating Major and Minor Strain
3.4 Measuring Circles
Exercise: Measuring Major and Minor Strain with Mylar
3.5 Recording and Plotting Measured Data
3.6 Introduction to Forming Limit Diagrams

4.0 Forming Limit Diagrams 
4.1 Why do we use Forming Limit Diagrams? 
4.2 Shape and Position of Steel Forming Limit Curves 
Exercise: Finding FLD0 by the Table Method and Calculation Method 
4.3 Shape and Position of Aluminum Forming Limit Curves 
4.4 Safety Margin 

Surface Stretch Analysis 
5.1 Where to use Surface Stretch Analysis  
5.2 Target Strain 
5.3 Dent Resistance 
5.4 Stiffness 

6.0 Results 
6.1 Interpretations of Results 
6.2 Limitations of TSA, CGA and Surface Stretch Analysis
6.3 Sample Report
6.4 Corrective Action 

Who should attend?
Tooling Supervisors, Tooling and Quality Engineers, and Tool and Die Makers. 

1 Day Course

Course Overview: Learn the fundamental design guidelines for Welding and Assembly. Emphasis will be placed on understanding the various types of assembly operations and how to ensure the design specified is feasible. Many guidelines for quality manufacture of assemblies are presented.  

Topic Covered:

• 1.0 Design Guidelines for Assembly Operations 
• 1.1 Methods and Terminology for Part Assembly  
• 1.2 Guidelines for Spot Welding Operations 
• 1.3 Guidelines for Projection Welding Operations 
• 1.4 Guidelines for MIG Welding Operations 
• 1.5 Guidelines for Self-Piercing Rivets (SPR’s) 
• 1.6 Welding Considerations for Different Materials 
• 1.7 Design for Laser Welding in Assembly  
• 1.8 Other Product Design Considerations 
• 1.9 Guidelines for Flanging and Hemming 
• 1.10 Summary  

Classroom Exercises:

• Exercise 1: Choosing Weld Locations for Assembly  
• Exercise 2: Assembly Terms and Guidelines 
• Exercise 3: Application for Assembly Guidelines 
• Who should attend?
• All types of Product, Process and Tooling Engineers, Product Designers and Body CAD personnel.

2-Day Course

Learn the inputs, concepts and requirements for design of dies for Transfer & Progressive Die Line-ups. This course provides the thought process & work flow for how a die design is established and the items to consider for building dies internally or sourcing to an outside supplier. Examples of how to ensure the design utilizes necessary die standards, press standards, production requirements & on-going maintenance will be provided. 

Course Outline 

1.0 Overview of Die Design 
1.1 Completed Die Design Package 
1.2 Die Design Terminology 
1.3 Types of Dies 
1.4 Building Dies Internally 
1.5 Sourcing Die Build to an Outside Supplier 
1.6 Summary 

2.0 Die Design Considerations 
2.1 General Die Construction &Materials 
2.2 Required Inputs to Die Design 
2.3 Press and Automation Requirements  
2.4 Using and Accessing Die Standards 
2.5 Panel or Part Set-Up 
2.6 Designing with Maintenance in Mind 
2.7 Die Design Checklist and Buyoff 
2. 8 Summary
3.0 Design Details for Transfer Dies
3.1 Draw Die Design 
3.2 Trim and Pierce Die Design 
3.3 Form and Flange Die Design 
3.4 Cam Die Design 
3.5 Summary 

4.0 Design Details for Progressive Dies 
4.1 Overview of Progressive Die Design 
4.2 Gutting and Pierce Stations 
4.3 Draw and Form Stations 
4.4 Cam Pierce, Trim and Form Stations 
4.5 Idle and Cutoff Stations 
4.6 Other Considerations for Progressive Die Design 
4.7 Summary 

Who should attend?
Tool Follow-up Engineers, Process Engineers, Tooling Supervisors, Process & Manufacturing and Engineers, Tool and Die Makers, Die Designers and Apprentices and those interested in the basic understanding of die design. 

8 Hour Training Course

Course Objective

Provide an overview of how to utilize scanning technology to effectively capture part & die scanned data. Examples will showcase gathering data for outer/inner panels, scanning parameters to consider and their effects, and techniques to maximize data quality for downstream use cases. Guidelines and preparation of this data for alignment, die maintenance, forming & welding simulation will also be presented.

Target Audience

Engineering, Quality and Plant personnel involved with the use/application of scanning technology or benchmarking of scanned data

Course Outline
 
1.0 Scanning Solutions for Stamping Manufacturing & Assembly
1.1 This section will cover the types of solutions used in the industry to capture part and die data. Comparisons of different technologies, uses cases, fixture/table scanning, parts cleaned or with lubricant, parts with reflective surfaces, point density, scanning speed and accuracy will be presented

2.0 Guidelines for Scanning Dies
2.1 This section will cover specific guidelines for how to scan dies, with specific examples on die alignment, die troubleshooting and damaged dies

3.0 Manufacturing Applications for Scanned Data
3.1 This section will cover typical manufacturing use cases for scanned data such as die maintenance, reverse engineering, and other quality issues. How to machine from scanned data will also be included

4.0 Stamping & Welding Simulation from Scanned Data
4.1 This section will cover how to prepare the scanned data for input to die and welding simulation. What questions/checklist to ask about the scanned data will be summarized.

1 Day Course

This course provides a detailed review of the types, application, and manufacturing issues of die sensors. Many examples of die sensors will be used to illustrate how the selection, die variables, and positioning can effect the overall die performance. Cost effectiveness for low and high-volume production will also be discussed. Exercises will require students to determine the type and position of a sensor for a specific function in a die. 

Course Outline: 

1.0 Die Sensing for Part and Die Components 
1.1 General description of sensors
1.2 Types of sensors and guidelines for sensor selection
1.3 Analogue and Go/No-go Sensors 

2.0 Sensor Placement 
2.1 Sensor positioning and installation 
2.2 Sensor adjustment 
2.3 Sensor sensitivity (mapping) 

3.0 Press Parameters 
3.1 Press control interface 
3.2 Methods of wiring and connection 
3.3 Junction box types 

4.0 Troubleshooting Sensors 
4.1 Typical sensor problems
4.2 Sensor protection 

5.0 Sensor Considerations
5.1 Sensor cost effectiveness 
5.2 New developments 

Who should attend?
Tooling, and Manufacturing Engineers, Designers, Tool and Die Makers. 

2-Day Course

Learn the thought process of how to create a draw development. This course provides the basic rules and concepts needed to understand how to design a draw development for quality stampings. Applications for outer and inner panels, and reinforcements are used to illustrate the effects of tip angle, drawbars, overdraw, etc. Students will work in-groups to determine and evaluate draw developments. 

Course Outline: 

1.0 Overview of Draw Die Development 
1.1 Overview of Draw Development Process 
1.2 Definition of Terms 

2.0 Establishing the Tip Angle 
2.1 Tip Angle for Outer Panels  
2.2 Tip Angle for Inner Panels  
2.3 Unfolding Flanges for Inner and Outer Panels  
Exercise: Determining the Tip Angle of an Inner Panel 

3.0 Understanding the Addendum 
3.1 Introduction 
3.2 Punch Opening Line 
3.3 Draw-Walls 
3.4 Drawbars 
3.5 Punch Extensions 
3.6 Gainers or Take-Up Beads 
3.7 Summary of Addendum Development 
Exercise: Determining the Addendum 

4.0 Understanding Binder Design 
4.1 Understanding Binder Design
4.2 Classification of Binder Shapes 
4.3 Blank Shape in a Closed Binder of a Single Action Press 
4.4 Blank Shape in a Closed Binder of a Double Action Press  
4.5 Details of Drawbeads 
Exercise: Evaluating a Draw Development  

5.0 Draw Die Development Applications 
5.1 Introduction 
5.2 Draw Die Development – Hood Outer Example 
5.3 Draw Die Development- Trunk Lid Inner Example 
5.4 Draw Die Considerations 
5.5 General Guidelines 
Exercise: Creating a Draw Development 

6.0 An Engineering Based Approach to Draw Die Development 
6.1 Engineering Perspective of a Draw Die Development 
6.2 An Application of the Engineering Approach 

Who should attend?
Process, Manufacturing, Tooling and Development Engineers and Tool and Die Makers.

1-Day Course

Learn the fundamentals for estimating the Material Blank Requirements, Tooling Costs and Engineering Changes for stampings. This course will provide examples of how to determine the material requirements and the preferred blank shapes for outer and inner panels. Methods and formulas for determining piece price and tooling costs will be provided. This course will also cover how to review, evaluate, and estimate typical Engineering Changes. 

Course Outline:  

1.0 An Overview of Stamping Estimating  
1.1 Preparing a quotation 
1.2 Selecting a Press Type or Process 

2.0 Material Utilization 
2.1 Determining the Blank Shape 
2.2 Preferred Blank Shapes for Outer Panels 
2.3 Preferred Blank Shapes for Inner Panels 

3.0 Estimating the Cost of Stamping the Component  
3.1 An Overview of the Factors that Affect Stamping Pricing 
Exercise: Stamping Cost Comparison of Typical Production Methods 
Exercise: Determining the Piece Price for a Part Produced from Manual Dies 
Exercise: Determining the Piece Price for a Part Produced from Transfer Dies 

4.0 Cost Estimating Tooling 
4.1 Determining the Cost of Tooling 
4.2 Estimating Tooling Development Time (Lead Time) 
4.3 Tooling Buy-off 
4.4 An Overview of Soft Die Development 

5.0 Costing Engineering Changes 
5.1 Estimating Changes to the Pierce Punch 
5.2 Evaluating Cam Piercing Changes 
5.3 Evaluating the Complexity of a Shape Change 
5.4 Estimating Times for Different Building Tasks 
5.5 Review of Engineering Change Estimate 
5.6 Typical Tool Shop Charges 

Who should attend?
Cost and Tooling Estimators, Stamping Buyers, Engineers & Managers, Purchasing, and Die Follow-up Personnel

2 Day Course ( 1 Day Classroom & 1 Day Hands-On)

Course Overview:  Learn the process for welding and repair of draw, trim/ pierce, flange and cam dies. Also learn to repair defects on panels using various welding and grinding methods. Emphasis is placed on proper techniques for tool steel welding and the ins-and- outs of press repair methods. Students will learn and practice proper techniques for welding and repair using MIG, TIG, and Stick applications. 

Topics Covered:  

• 1.0 Welding Overvie
  • 1.1 Types of Welding and Equipment
    • GTAW Gas Tungsten Arc Welding (TIG), SMAW Shielded Metal Arc Welding (Stick)
    • GMAW Gas Metal Arc Welding (MIG), Choosing the proper equipment

• 1.2 Welder Settings for Different Types of Die Steels
• 1.3 Pre-Heating and Steel Preparation
  • Estimating temperature change by color
• 1.4 Welding Rod Types
  • 0-1, A-2, D-2C, Cast Steel, Aluminum

• 2.0 Draw Die Weld Repair
  • 2.1 Draw Bead Repair
    Fixing a Bead by Welding, Grinding, and Polishing
  • 2.2 Repairing a Welded Flat Surface
    Steps to Welding, Grinding, and Stoning a Flat Surface by Hand
  • 2.3 Repairing a Welded Curved Surface
    Steps to Welding, Grinding, and Stoning a Curved Surface by Hand
  • 2.4 Repairing a Welded Feature Line
    Steps to Successfully Blend a Welded Feature Line

• 3.0 Trim Die Weld Repair
  • 3.1 Punch Trim Line Repair
    Fixing Cutting Problems Associated with Burrs by Welding
  • 3.2 Die Trim Line Repair
    Fixing Cutting Problems Associated with Burrs by Welding
  • 3.3 Trim Line Change to Reduce Panel Size
    How to Successfully Move a Trim Line by Welding
  • 3.4 Trim Line Change to Increase Panel Size
    How to Successfully Move a Trim Line by Welding
  • 3.5 Scrap Cutter Repair
    Steps to Grinding a Welded Inserted Cutter

• 4.0 Pierce Die Weld Repair
  • 4.1 Pierce Die Repair
    How to Grind Welded Cutting Edges
  • 4.2 Pierce Punch Repair
    How to Grind Welded Cutting Edges

• 5.0 Flange Die Weld Repair
  • 5.1 Verifying Flange Clearance
    Steps to Successfully Establish Proper Clearances
  • 5.2 Flange Line Change to Reduce Panel Size
    Using Plotted Points to Successfully Grind a Welded Bend Line
  • 5.3 Flange Line Change to Increase Panel Size
    Using Plotted Points to Successfully Grind a Welded Bend Line

• 6.0 Production Die Repair & Welding  
  • 6.1 Cracking and Wrinkling 
    What to look for and ways of fixing Panel Conditions during Production 
  • 6.2 Panel Stoning and Deforms 
    Identifying the Common Types of Deforms by Panel Stoning 
  • 6.3 Emergency Repairs for Negative Deforms 
    Temporary Time Saving Repairs for Draw Dies that can Reduce Press Downtime 
  • 6.4 Emergency Trim Line Repairs 
    Temporary Time Saving Repairs for Draw Dies that can Reduce Press Downtime 

• 7.0 Hands-On Welding Applications- 8 Hours 
  • 7.1 GTAW-TIG Welding 
    Students perform a variety of welding applications 
  • 7.2 SMAW- Stick Welding 
    Students perform a variety of welding applications 
  • 7.3 GMAW- MIG Welding
    Students perform a variety of welding applications 

 Who should attend?
Tooling Supervisors, Process, Manufacturing and Tooling Engineers, Tool and Die Makers and Plant Welding Personnel

 2 Day Course

Course Overview: Learn how to evaluate parts for welding defects associated with resistance, MIG, and projecting operations. Students will learn the troubleshooting skills necessary to address weld quality issues and suggest potential counter measures in the automotive manufacturing environment. 

Topic Covered:

• 1.0 How a Weld is Made 
  • 1.1 Resistance Spot Welding
  • 1.2 Characteristics of the Weld Nugget 
  • 1.3 Making a Spot Weld  
    • Single Spot 
    • Double Spot 
    • Projection Weld 
  • 1.4 Relationship of the Welding Variables 
    • Single Spot 
    • Double Spot 
    • Projection Weld 
  • 1.5 The Elementary Welding System 
    
    
• 2.0 Weld Schedules Metals and Other Variables 
  • 2.1 Resistance Spot Welding 
  • 2.2 Basic Welding Circuit
    • Producing Weld Heat 
    • Spot and Projection Welding Components 
    • Electrodes and Other Current-Carrying Members 
    • Pressure System 
  • 2.3 Weld Sequence 
    • Squeeze 
    • Weld Time 
    • Hold 
  • 2.4 Welding Variables (Single, Double, Projection Welds) 
    • Weld Circuit Effects on Weld Heat 
    • Current and Voltage 
    • Electrode Face Area
    • Time 
    • Weld Loop Impedance 
    • Electrode Force  
      
      
• 3.0 Protective Coatings and Contaminants
  • 3.1 Galvanized Steel
    • Hot Dipped
    • Electroplate
  • 3.2 Contaminants on the Metal
    • Drawing Compound
    • Dirt and Scale
    • Oils
    • Rust
    • Sealer
  • 3.3 Composition of Metal (Metallurgy)
    • Weld Heat Balance
    • Equal Thickness
    • Unequal Thickness 

• 4.0 Weld Schedules 
  • 4.1 Weld Tables 
    • Three-ply Weld Schedule 
      
      
• 5.0 Weld Quality Defects (Spot and Projection Welds) 
  • 5.1 Surface Defects 
    
    • Indentation 
    • Surface Deformation Surface Burning 
    • Surface Expulsion (Whiskers) 
    • Cracks
    • Blow Holes 
  • 5.2 Weld Nugget Defects 
    •  Undersize Nugget 
    • Low Penetration 
    • Porosity 
    • Expulsion 
    • Misshapen Weld Nugget 
    • Poor Part Fit-up 
    • Fixture Related Issues 
    • Poor Electrode Alignment  
  • 5.3 Corrective Action for Eliminating Spot Weld Defects 
    • Correction of Surface Defects 
    • Correction of Weld Nugget Defects 
      
      
• 6.0 General Maintenance 
  • 6.1 Weld Schedules 
  • 6.2 Caps  
  • 6.3 Water Tubes 
  • 6.4 Contaminants on the Metal 
  • 6.5 Guns 
  • 6.6 Cables 
  • 6.7 Fixtures 
    
    
• 7.0 Troubleshooting 
  • 7.1 Generic Weld Inspection Process 
    • Destructive Testing 
    • Non-Destructive Testing (W&A) 
  • 7.2 Troubleshooting Flow Chart 
  • 7.3 Welding Sequence Consequences 
    • Spot and Projection Welding 
    • MIG Welding 
    • Laser Welding 
      
      
• 8.0 Exercises 
  Interactive hands-on exercises designed to introduce the students to the troubleshooting process: 
  Exercise 1: Identifying Common Spot Weld defects 
  Exercise 2: Evaluating Spot Weld Defects on Assemblies 
  Exercise 3: Identifying Common Projection Weld Defects 
  Exercise 4: Identifying Common MIG Weld Defects 
  Exercise 5: Evaluating MIG Weld Defects on Assemblies 
  Exercise 6: Evaluating Projection Weld Defects on Assemblies 
  Exercise 7: Rework Methods for Weld Defects

Who should attend?
All types of Engineers, Product Designers, Tool and Die Makers, Welding Maintenance, and Launch Personnel.

 

1 Day Course

Course Overview: Learn the processes and equipment used in resistance (spot) welding. You will review: basic resistance welding, how welds are made, components and mechanics of a welding system, pneumatic and hydraulic systems, testing methods and weld schedules for various materials and coatings. 

Topic Covered:

• 1.0 How a Weld is Made 
  • 1.1 Resistance Spot Welding 
  • 1.2 Characteristics of the Weld Nugget 
  • 1.3 Making a Spot Weld 
  • 1.4 Relationship of the Welding Variables 
  • 1.5 The Elementary Welding System 
    
    
•  2.0 Welding Fixture Secondary Components 
  • 2.1 Introduction 
  • 2.2 In-line Weld Gun Assembly 
  • 2.3 Welding Electrodes (caps) 
  • 2.3 Electrode Holder Assembly 
  • 2.4 Threaded Adapters 
  • 2.5 Tapered Shank Cap Adapters (Barrels) 
  • 2.6 Offset Electrode Caps and Adapters 
  • 2.7 Water Tubes and Water Tube Adapters 
  • 2.8 In-line Welding Gun Cylinders 
  • 2.9 Stationary Back-up Electrodes 
  • 2.10 Secondary Conductors (Shunts) 
  • 2.11 Welding Fixture Transformers 
  • 2.12 Weld Circuit and Power Considerations 
  • 2.13 Primary Circuit Power Control 
  • 2.14 Secondary System Mechanical Arrangement 
    
    
•  3.0 Positioning and Holding Production Parts 
  • 3.1 Magnetic Losses 
  • 3.2 Electrical Switches 
  • 3.3 Water Distribution  
  • 3.4 Fixture Color Codes 
    
    
•  4.0 Multiple Welding Secondary 
  • 4.1 Weld Power Supply 
  • 4.2 Weld Loop Impedance 
  • 4.3 Types of Resistance Welding 
  • 4.4 Balanced Welding Conditions 
  • 4.5 Classes of Welds 
    
    
•  5.0 Portable and Robot Spot Welding 
  • 5.1 Portable Weld Guns 
  • 5.2 Portable Weld Gun Designs 
  • 5.3 Transformer Secondary Cables 
  • 5.4 Portable Welder Suspension Systems 
  • 5.5 Robot Integral Weld Guns 
  • 5.6 Color Coding of Components  
  • 5.7 Weld Gun Assembly  
  • 5.8 Portable and Robot Welding Standards 
    
    
•  6.0 Weld Schedules, Metals and Other Variables 
  • 6.1 Resistance Spot Welding  
  • 6.2 Basic Welding Circuit  
  • 6.3 Weld Sequence 
  • 6.4 Welding Variables 
  • 6.5 Protective Coatings 
  • 6.6 Contaminants on the Metal 
  • 6.7 Composition of Metal (Metallurgy) 
  • 6.8 Weld Heat Balance 
  • 6.9 Metals Commonly Resistance Spot Welded 
  • 6.10 Multiple Thickness Welds 
  • 6.11 Spot Spacing 
  • 6.12 Weld Schedules 
    
    
•  7.0 Weld Quality and Testing Methods 
  • 7.1 Spot Weld Defects 
  • 7.2 Corrective Action for Eliminating Spot Weld Defects 
  • 7.3 Welding Equipment Testing and Troubleshooting 
  • 7.4 Secondary System Maintenance 
  • 7.5 General Maintenance 

 Who should attend?
All types of Engineers, Product Designers, Tool and Die Makers and anyone interested in an overall understanding of resistance welding.

The purpose of this course is to introduce the new Marc user to both Marc and Mentat by lectures and hands on modeling of nonlinear problems.

Length: 

3 Days

Pre-requisites : 

A basic knowledge of statics and strength of materials is highly recommended. Previous finite element analysis experience is recommended

Topics: 

• Introduction to Mentat
• Nonlinear Finite Element Analysis
  • Geometrically Nonlinear Analysis
  • Material Nonlinear Analysis
  • Modeling with Contact
• Resolving Convergence Problems
• Numerical Analysis of Nonlinear Problems

The purpose of this course is to enhance the current Marc user's understanding of modeling nonlinear problems. Lectures are supported by hands-on modeling of nonlinear problems.

Length: 

3 days

Pre-requisites : 

A basic knowledge of nonlinear simulations - Familiarity with Mentat 2011 - Completion of MAR101 (Basic Nonlinear Analysis using Marc and Mentat) or equivalent experience

Topics: 

• Material Nonlinearity
• Contact
• Adaptive Meshing
• User Subroutines in Marc
• Heat Transfer and Thermal Stresses
• Global - Local (Structural Zooming) Analysis in Marc
• Restarts
• Performance

• Workshop Problems
  • Experimental Curve Fitting Using Physical Test Data
  • Creep of Tube
  • Superplastic Forming of a Metal Container
  • Composite Progressive Failure Analysis using VCCT
  • Elastomeric Cylinder (Segment to Segment Contact)
  • Ship Bumper Contact Analysis
  • Global Remeshing
  • Local Adaptive Remeshing
  • Creep of a Tube (User Subroutine)
  • Heat Transfer (Conduction and Convection)
  • Heat Transfer (Radiation)
  • Coupled Analysis (Thermal / Structural)
  • Global – Local (Structural Zooming)
  • Restarts

This course provides an overview of general electromagnetic theory and of the theory behind different analysis types in Marc Electromagnetics and the typical problems they can handle. It provides a quick review of Marc nonlinear methodology and contact analysis as well as of Marc Structural and thermal analysis. For each analysis type, the workshops are chosen to show a range of problems that can be solved in Marc. Each workshop shows detailed step by step finite element modeling in Mentat and is a quick, simple and efficient way of learning Mentat. The post-processing section of each workshop problem illustrates how finite element results can be interpreted, and how they can be used to obtain other practical quantities. Relevant short notes at the end of a workshop help in getting additional information about Marc and Mentat.

Length: 

3 days

Pre-requisites : 

None

Topics: 

• Day1
  • Main theory of EM and Electrostatic workshop
• Day2
  • Joule-thermal-structural and Magnetostatics=structural workshop
• Day3
  • Piezoelectric , magnetostatic-thermal and magnetodynamics workshop

Online Self-Paced Course
Course Materials, Workshops with Model Files

The purpose of this course is to provide a fundamental understanding of how material testing and finite element analysis are combined to improve the design of rubber and elastomeric products.

Topics:

• Introduction
• Overview of Elastomer Testing and Analysis
  • Test data are dependent on the measurement method
  • Analysis results are dependent on the mesh
  • Measurement and Modeling principals
• Uniaxial Tension/Compression Testing and Analysis
  • Specimen setup and test
  • Set up model - Curve Fitting of Uniaxial Material Data
  • Run Simulation
  • Understand Physical and Numerical Results
• Biaxial Tension/Compression Testing
  • Specimen setup and test
  • Set up model - Curve Fitting of Multi Mode Material Data
  • Run Simulation
  • Understand Physical and Numerical Results
• Pure Shear Testing
  • Specimen setup and test
  • Set up model - Curve Fitting of Multi Mode Material Data
  • Run Simulation
  • Understand Physical and Numerical Results Contact Analysis
• Product Simulations with Specimen Data
  • Definition of contact bodies
  • Contact and friction
  • Case Histories of Product Simulation

Online Self-Paced Course
Course Materials, Workshops with Model Files

The purpose of this course is to provide a fundamental understanding of how material testing and finite element analysis are combined to improve the design of rubber and elastomeric products.

Topics:

• Introduction
• Overview of Elastomer Testing and Analysis
  • Test data are dependent on the measurement method
  • Analysis results are dependent on the mesh
  • Measurement and Modeling principals
• Uniaxial Tension/Compression Testing and Analysis
  • Specimen setup and test
  • Set up model - Curve Fitting of Uniaxial Material Data
  • Run Simulation
  • Understand Physical and Numerical Results
• Biaxial Tension/Compression Testing
  • Specimen setup and test
  • Set up model - Curve Fitting of Multi Mode Material Data
  • Run Simulation
  • Understand Physical and Numerical Results
• Pure Shear Testing
  • Specimen setup and test
  • Set up model - Curve Fitting of Multi Mode Material Data
  • Run Simulation
  • Understand Physical and Numerical Results Contact Analysis
• Product Simulations with Specimen Data
  • Definition of contact bodies
  • Contact and friction
  • Case Histories of Product Simulation

Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
This course explains the enhancement topics in new Marc release.

This course provides an introduction to the MSC Apex Python Scripting API. The course is structured to provide an experienced python user with an overview of the API, instructions on using the API documentation, and hands-on examples.

Pre-requisites:
Some knowledge of Python and MSC Apex is recommended but not required.

Topics Covered:

• Overview of the MSC Apex Python Scripting API
• Apex Macro Record and Customization
• Apex Model Management and API
• MSC Apex Script Triggers
• Apex Custom Tools and Python GUI SDK
• External Python IDE and Using third party packages

MSC Apex Learning Modules
Online Self-Paced Course
Course Materials, Workshops with Model Files

Topics:

• Basics of Finite element analysis
• Purpose Driven Finite Element Analysis using MSC Apex
• 2.5D meshing
• Loads and Boundary Conditions in MSC Apex
• Interaction Tools in MSC Apex 
• Model Checks in MSC Apex
• Normal Modes Analysis in MSC Apex
• Buckling Analysis in MSC Apex 
• Frequency Response in MSC Apex
• Post-processing in MSC Apex

MSC Apex Curriculum kit

About this Course:
This course is an introduction to the Generative Design world and its new mindset. It shows and explains the concept behind generative design, what is different to familiar technologies and what we want to achieve with it. The success of the software is presented through a few Use Cases.

Pre- Requisites
NA

Topics covered

• The goal of Generative Design
• Why we need to go beyond topology optimisation
• Rethink the existing workflow
• Variety as a key for successful designs
• Design funnel for optimal designs
• Cost reduction by Generative Design
• Design for sustainability
• Industry overview
• Selected, successful use cases
• Hardware information: technical suggestions

24 hours –Online Self-Paced Course
Course Materials with audio from Subject Matter Experts, Workshops with Model Files, and Demo Videos

About this Course:
Beginner: This course provides an introduction to finite element analysis. It includes discussion of basic features available in MSC Nastran for solving structural engineering problems. In this course, all finite element models will be created and edited using a text editor, not a graphical pre-processor.

40 hours - Online Self-Paced Course Course Materials, Workshops and Model Files

About this Course: PAT301A is the introductory course for new Patran users. Students will master the basic skills required to use Patran in typical MCAE applications. PAT301A emphasizes practical skills development through comprehensive, hands-on laboratory sessions. Students will learn to build analysis models using Patran, define material properties, create boundary conditions, apply loads, and submit their job for analysis and postprocess results.

32 hours – Online Self-Paced Course
Course Materials, Workshops and Model Files

About this Course:
PAT301B provides an in-depth examination of the advanced features of Patran. Sample topics covered by PAT301B include: advanced Patran features usage for meshing and mesh refinement, use of various Patran Command Language (PCL) files for session customization, application of advanced geometric construction techniques, definition of fields to represent spatially varying functions for loads and boundary conditions, generation of constraint equations (MPCs) to define physical relationships, and creation of sophisticated multi-effect graphical images.

40 hours –Online Self-Paced Course
Course Materials, Workshops and Model Files

About this Course:
PAT304 provides students with an overview of the Patran Command Language (PCL). Topics include basic PCL syntax, creation of a user interface object; compiling, debugging, and code management. Students will build practical skills by performing 11 PCL programming exercises in multiple laboratory sessions.

Course Description:
Intensive review of Patran focusing on building heat transfer models for Thermal. Initial overview of Thermal capabilities followed by exposure to all features of Thermal accessed through Patran. Each lecture and lessons will instruct you how to setup, execute, and post process the results of a heat transfer analysis. Lessons increase in the level of detail and complexity through the week.

Pre-requisites: Background using thermal analysis with either finite difference or finite element formulations. PAT301(Introduction to Patran) or equivalent experience in the use of Patran.

Topics:

• Analyzing models which include the four basic modes of heat transfer
• Exercising the two primary types of heat transfer analysis
• Defining thermal materials
• Describing and applying available element types and options
• Defining heat transfer loads and boundary condition that are either constant or variable for
• Programming user supplied subroutines to
• Using the built in hydraulic network solver and its associated element and boundary definitions.
• Accessing and customizing control parameter

16 hours – Online Self-Paced Course
Course Materials, Workshops and Model Files

About this Course:
This course introduces methods for evaluation and estimation of fatigue life using MSC Fatigue. Various approaches for extending the useful life of a design are discussed. In addition, design optimization based on a uniform life concept, and selection and evaluation of material surface finish and treatments, will also be covered.

16 hours –Online Self-Paced Course
Course Materials, Workshops and Model Files

About this Course:
Advanced Durability and Fatigue Life Analysis Using MSC Fatigue

16 hours – Online Self-Paced Course
Course Materials, Workshops and Model Files

About this Course:
This seminar shows outlines of composites materials theory and the integration between FEM and composites materials. Illustrate the basic functions of Patran Laminate Modeler and Composite design in MSC Nastran. Engineers and material scientists involved in the design, analysis and manufacture of composite components and structures would benefit from this seminar.

Online Self-Paced Course
Course Materials, Workshops with Model Files

This course is intended for users that have fundamental CATIA V5 knowledge. Experience with Part Design, Assembly Design and DMU Kinematics workbenches is recommended.

Topics:

• Transform kinematics CATIA V5 models to Adams Solver friendly mechanisms.
• Convert assembly constraints to mechanism constraints:
  • Standard joints (hinges, sliders, etc...)
  • Joint primitives
  • Complex (couplers, etc...)
  • Curve (cam-follower, pin-in-slot)
• Actuate a system with:
  • Ideal and complex part motion
  • Applied forces
  • Gravity
• Connect parts with more realistic forces:
  • Simple (springs,dampers, etc...)
  • Contacts and collisions
• Measure quantities of interest (displacements, velocities, accelerations, applied loads, forces)
• Precisely control and manage your simulations
• Investigate test results via animations and plots
• Manage files generated by exporting from CATIA V5 interface to Adams View and/or Adams Solver

Online Self-Paced Course
Course Materials and Workshops

Online Self-Paced Course
Course Materials, Workshops with Model Files

Topics:

• Module 1 - Overview
• Module 2 - GUI Files
• Module 3 – Materials
• Module 4 - Element Properties
• Module 5 - Fields
• Module 6 - Loads and Boundary Conditions
• Module 7 - Analysis
• Module 8 - Output and Results