AutoForm Applies Springback Compensation in Metal Stamping
 ZURICH,
Switzerland, Jan 20, 2010 - AutoForm Engineering Deutschland GmbH, on a
project in collaboration with Schuler Cartec GmbH & Co. KG, has demonstrated
how to successfully apply springback compensation on a routine task.
Springback simulation has achieved such good results that its implementation
in industry is beyond question. Springback compensation is the next logical
step. Both companies worked together analyzing a tricky side member for
Daimler’s E-Class model.
The influence of a drawbead (bead 1) on a specific output value
after the sensitivity analysis is carried out by AutoForm-Sigma
With its curved shape in all three axial directions, the side member is a
complex stamping part. Bent flanges add additional stresses to the part and
numerous add-on parts demand a high level of accuracy. The part is made of
ZStE 340 which is a high strength, widely-used but challenging material.
What is remarkable about this part is that not only one, but three
operations are individually compensated, which therefore increases its
complexity. In addition, there are tolerance bands, to some extent
single-sided, which are only some tenths of a millimeter.
Trim line development is based on trim analysis by using AutoForm
Tooling and Tryout Solution
Using AutoForm Tooling and Tryout Solution, Schuler Cartec validates the
process layout and the draw die design, carries out a trim analysis and
optimizes trim lines. AutoForm Engineering broadens the analysis. After the
springback calculation has been made, the results are used to compensate the
die faces with the help of AutoForm-Compensator. In the final validation
stage, AutoForm-Sigma demonstrates the robustness of the forming process and
springback under real manufacturing conditions, i.e. with variations of
material and process parameters. The consideration of these parameters
already during the design phase ensures a robust manufacturing process. This
is how springback compensation leads to dimensionally stable parts. A great
benefit is that the only possible expense up to this point is attributed to
the simulation effort since production has not yet started.
Besides the robustness analysis by AutoForm-Sigma which considers
inherent variations, AutoForm Engineering uses a sensitivity analysis to
determine the influence of design parameters such as initial blank, binder
force, friction coefficient and drawbeads. The influence of the first three
parameters is unremarkable. Two drawbeads, however, show a high, locally
limited influence regarding material failure. The effect of the two other
drawbeads is similarly strong, but more extensive and in an unexpected area
of a part. The simulation shows that these parameters have a great influence
on the material failure. The new insight gained by using AutoForm software
prevents unnecessary correction loops which represent serious costs in the
tryout press.
The tryout phase in the tryout press begins after the manufacturing of
tool components and tool assembly. The first correction loop is followed by
the next one, however only after an additional compensation in particular
areas was made. The results are convincing. Instead of the usual three to
four correction loops, the dimensional specifications of the parts are
achieved even after just two of them. Helmut Gründler, Assembly Manager and
responsible for the tryout, experiences an immediate benefit. He explains:
“Just a few years ago, I would have considered a part with such tolerance
bands as not feasible. Today, we can produce such parts even when using
challenging, modern materials.”
The increased software usage at the starting phase of this project, which
included springback compensation and final validation of tools, has proven
itself by demonstrating immediate benefits. In addition, a time savings of
eight weeks is achieved.
About Schuler Cartec GmbH & Co. KG
Schuler Cartec GmbH & Co. KG is the world leader in forming technology
for metal working. Schuler Cartec represents the Schuler Werkzeugbau with
locations in Göppingen and Weingarten. Schuler Werkzeugbau develops and
manufactures challenging tool systems of all sizes, which are used, for
example, for sheet metal body parts, hot forming parts and parts for
transmission. The core competencies in the Weingarten plant lie in the
development and planning as well as engineering, tool manufacturing and
tryout. Process simulations are standard in order to optimize the
manufacturing and material usage.
For more information, visit
www.schulergroup.com.
About AutoForm Engineering GmbH
AutoForm offers software solutions for the die-making and sheet metal
forming industries along the entire process chain. With over 200 employees,
AutoForm is recognized as the leading provider of software for product
manufacturability, tool and material cost calculation, die face design and
virtual process optimization. All of the Top 20 automotive OEMs and most of
their suppliers have selected AutoForm as their software of choice. Besides
its headquarters in Switzerland, AutoForm has offices in Germany, The
Netherlands, France, Spain, Italy, USA, Mexico, India, China, Japan and
Korea. AutoForm is also present through its agents in more than 15 other
countries.
For more information, visit
www.autoform.com.
----------
If news like this is important to you,
sign up for TenLinks Daily, our free
newsletter.
----------
See Also
AutoForm
website
CAD - Sheet Metal Design - by TenLinks.com
Additional News
Jan 20 - AutoForm Applies Springback Compensation in Metal Stamping
Nov 17 - AutoForm Develops Hot Forming Simulation Process
Sep 29 - AutoForm Develops Pilot Models for Progressive Die Stamping
Sep 8 - AutoForm Develops Cost Optimized Process Plan Module
Jul 7 - AutoForm Develops Kinematic Hardening Model
Mar 31 - AutoFormplus Products Unveiled for Sheet Metal Forming
Mar 17 - AutoForm Wins Swiss Venture Club Award for Entrepreneurs
Oct 23 - AutoForm EasyBlank Add-On Includes Feasibility, FLD Diagram
Oct 17 - AutoForm v4.2 Unveiled for Sheet Metal Forming
Aug 25 - AutoForm Opens Office in Hong Kong
Jul 30 - AutoForm EasyBlank Add-On Module Imports CAD Files
Source: Material used in press releases is often supplied by external
sources and used as is. |
