When using a tool like AutoForm to design die faces, with the intent of simulating the design for verification, there is a basic path or set of steps that are used to end up with a die face design.
We will now briefly out line such steps. As we have mentioned in many of our blogs, a complete CAD model is needed that as radii. The first and foremost step is always a blank shape estimate, but this is not really part of a die face design, rather it is an indication of material usage for budgeting purposes and later use in simulation. So actually, the first step in a die face design is to inspect the geometry of the part and perform an undercut check.
If it is possible to form all of the part’s shape in a single form stage (be it crash form or a draw) then an attempt is always made to do so. This is done by tipping the part’s geometry into the most favorable pressing angle, then extending and adding additional geometry (where needed) to ensure that the blank will be “captured” by the tooling surfaces and formed correctly
From this point, the die face design starts to differ from the final part’s geometry. Pre-draw geometry must be created that carefully considers the problems encountered in the single stage forming simulation. For example, a deep drawn cup shape may need an over drawn bowl shape to start with. This is where the software does not magically come up with a die face design and the skill and experience of the die face designer is required to produce suitable geometry.
Of course, the huge advantage is that many different variations can be tried and tested in the virtual environment to get the pre-draw shape just right, before a tool is manufactured. Furthermore, if either of the form stages require draw beads to help control material flow (to prevent problems like wrinkling) then draw beads can be simulated too.
Again, the software is not magical and placement, length, shape and size of draw beads needs to be considered by the die face designer. The determination of such parameters for draw beads is again based on the results seen in the single stage form OR the results seen in a draw stage WITHOUT draw beads. The great thing about using forming simulation is that experiments with different types, lengths and placements of draw beads can be performed for little expense and the best result can be chosen for use in an actual tool build.
Once all die faces of each forming stage (including draw beads, if required) have been designed and tried in the virtual environment, the final virtual part can be subjected to a springback check. If the amount of springback is un-acceptable in the final part, then a further die face design revision can be made in any of the form stages, to countermeasure the predicted springback.
Finally, once satisfaction with all the simulation results is achieved, all die faces that were used in the simulation are converted to CAD and exported for use in an actual tool build.
About StampingSimulation.com
StampingSimulation.com is a world wide team of specialist forming simulation and sheet metal forming engineers. With resources across three continents (North America, Europe and Australasia) we are uniquely placed to offer fast turn around times on all structural simulation, hydro forming simulation, ANSYS simulations and sheet metal forming simulations.
About AutoForm
AutoForm offers software solutions for the die-making and sheet metal forming industries, and is recognized by the Top 20 automobile producers and their customers, as the number one provider of software for product formability, die face design and virtual tryouts to the global automotive industry.
The use of AutoForm software improves reliability in planning, reduces the number of die tryouts and tryout time, and results in higher quality part and tool designs that can be produced with maximum confidence. In addition, press downtime and reject rates in production are substantially reduced.
We will now briefly out line such steps. As we have mentioned in many of our blogs, a complete CAD model is needed that as radii. The first and foremost step is always a blank shape estimate, but this is not really part of a die face design, rather it is an indication of material usage for budgeting purposes and later use in simulation. So actually, the first step in a die face design is to inspect the geometry of the part and perform an undercut check.
If it is possible to form all of the part’s shape in a single form stage (be it crash form or a draw) then an attempt is always made to do so. This is done by tipping the part’s geometry into the most favorable pressing angle, then extending and adding additional geometry (where needed) to ensure that the blank will be “captured” by the tooling surfaces and formed correctly
Of course, the huge advantage is that many different variations can be tried and tested in the virtual environment to get the pre-draw shape just right, before a tool is manufactured. Furthermore, if either of the form stages require draw beads to help control material flow (to prevent problems like wrinkling) then draw beads can be simulated too.
Again, the software is not magical and placement, length, shape and size of draw beads needs to be considered by the die face designer. The determination of such parameters for draw beads is again based on the results seen in the single stage form OR the results seen in a draw stage WITHOUT draw beads. The great thing about using forming simulation is that experiments with different types, lengths and placements of draw beads can be performed for little expense and the best result can be chosen for use in an actual tool build.
Once all die faces of each forming stage (including draw beads, if required) have been designed and tried in the virtual environment, the final virtual part can be subjected to a springback check. If the amount of springback is un-acceptable in the final part, then a further die face design revision can be made in any of the form stages, to countermeasure the predicted springback.
Finally, once satisfaction with all the simulation results is achieved, all die faces that were used in the simulation are converted to CAD and exported for use in an actual tool build.
About StampingSimulation.com
StampingSimulation.com is a world wide team of specialist forming simulation and sheet metal forming engineers. With resources across three continents (North America, Europe and Australasia) we are uniquely placed to offer fast turn around times on all structural simulation, hydro forming simulation, ANSYS simulations and sheet metal forming simulations.
About AutoForm
AutoForm offers software solutions for the die-making and sheet metal forming industries, and is recognized by the Top 20 automobile producers and their customers, as the number one provider of software for product formability, die face design and virtual tryouts to the global automotive industry.
The use of AutoForm software improves reliability in planning, reduces the number of die tryouts and tryout time, and results in higher quality part and tool designs that can be produced with maximum confidence. In addition, press downtime and reject rates in production are substantially reduced.
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