Die Design and Simulation

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1 Die Design and Simulation May 29, 2014 Cimatron Technologies, Inc.

2 Agenda! In this presentation, you will see:! Part forming simulation in practice! Spring back issues! Part failure issues! Techniques on fixing issues as aided by simulation! Tool collision issues! Tool motion simulation! Case Study: Rezmin Tool & Die Quit losing money because of rework! 2

3 Today s Presenter David Lindemann Application Engineer

4 About Cimatron! World leader in CAD/CAM solutions for mold, tool and die makers; mfg. of discrete parts! 32 years of expertise! Operations in 35 countries! 40,000+ installations! Cimatron customers deliver tools faster than the industry best-in-class Cimatron Headquarters

5 Spring back: The Challenges Difficult to predict Time consuming to understand the effects Costly to fix tooling Consumes design time redesigning die Were these costs in the quote?

6 Spring back Magnitude of change Deflection Collection of real information before tooling the part Avoid reworking the tooling

7 Spring back More than moving part surfaces Spring back affects radius and bend as well as flange 3D model tough enough how would you fix this in 2D? Dedicated modelling tools to address this

8 Spring back Surfaces confined as no affect by the spring back Points on edge most affected specifically chosen to calculate spring back correction

9 Spring back Is material thickening? Is it straining? Is it wrinkling? Will overbending to reduce spring back create failure?

10 First Case: Spring back REAL LIFE!! Much more challenging! REAL LIFE!!

11 Spring back Deflection all over and large Cold rolled HSLA 340.9mm thick 450mm x 950mm 17 ¾ x 37 ½ Rework tooling? Red 1.5mm Blue 3.2mm

12 Spring back Keep original part data but apply it to die surfaces Collect data as points showing deviation

13 Spring back Points of deflection saved off of part data Applied to part or die surfaces Analysis dependent on material properties and gage

14 Spring back Orginal part data remains die surfaces altered 95% in tolerance clamped 83% in tolerance unclamped 20 hours design saved NO REWORK!

15 Second Case:! Nortool is one of several brands or divisions of Norco Industries all privately owned in Elkhart IN.! Norco was established in 1964 and supplies a wide array of product line for automotive, RV, and heavy duty lifting equipment. Included in the different brands Norco offers are E-coat and powder coat finishing and stabilizing and tongue jacks! Nortool as a brand specializes in:! High and low volume precision machining! CNC and Wire EDM, including high speed 4 axis machining! Tool and die work! Gauge work! Assembly and welding of machine components! Machine repair! ISO 9001 :2000

16 Nortool Nortool is equipped to support all other brands of Norco and additional customer needs:! Progressive dies for automotive and after market! Unique assembly and bending equipment! Special custom order machining! Prototyping and tryout of machined components and metal formed components! Laser cutting! Precision grinding! Wire EDM! Lathe! High speed multi-axis machining

17 Nortool! Services include:! Design and Engineering Assistance! Metal form analysis! Product testing and feasibility! Die design! Die making

18 Nortool! Works with clients from idea conception to project completion! Includes the product itself and the process to make it! Clients include world-leading companies such as:! Flo- Dynamics! Adnik! BAL! Midwest Benders! Genesis Molding! Navistar

19 Management Objectives! Cost reduction and control! Increase productivity and reduce lead time! Increase customer satisfaction! Increase employee motivation! More competitive! Diversify

20 CAD/CAM Objectives Implement 3D Die Design Direct communication between the design team and shop floor Improve machine time and capability Improve external data communications Unify on one software platform across departments Improve quoting process

21 Overcoming The Challenges! What Nortool does differently! Process! Tight interaction with our customers (early involvement) Product idea is taken step-by-step through the process from CAD design through production and assembly Give clients suggestions to optimize manufacturability Assist in selection of finishes, treatments etc. Define proper material thicknesses and other details for solid tooling concepts! Hold responsibility for ensuring the die is robust and will produce high-quality parts Emphasize extensive design review and analysis

22 Overcoming The Challenges Technology! Nortool uses CimatronE as a single, completely integrated solution throughout the entire design and manufacturing process Other things we tried prior to unifying on Cimatron! Several different software packages were being used! Work was hindered by different departments functioning on separate platforms

23 Overcoming The Challenges! How Cimatron helps! Cimatron has applications that are specifically geared towards our industry! Nortool diemakers and programmers are doing everything in Cimatron! Biggest advantage was in strip design! Process time in design and on floor reduced due to 3D design! Extra perk - benefited the quoting department! Outstanding technical support & training!! Process exceeded expectations!

24 Conclusion! Improved overall communications! Cost Control! Increased productivity! Faster time to market! Management of ECO (Engineering Change Order)! Elimination of user error! Increased customer satisfaction! Increased employee motivation

25 Second case : Part Failure Part tears across knuckles Over stretching 2D design No analysis before tooling Die and punch inserts scrapped Guess the part in make changes in tool until I get it right

26 Include new station Increase size of corner radii in form section Form walls at angle Top of part is higher Strain analysis shows this will work Restrike

27 Final form shown in green Transitional form shown in gray Finish part higher than transitional part Different radius and angle on walls

28 RESTRIKE Formed the final smaller radius Wipe the walls down straight Put radius into compression

29 3D modelling Analysis at each station to show results of each action

30 2D VS 3D Why use 2D? Because shop already has it Can you find the interference?

31 2D VS 3D V block from station has interference with the part on the strip 2D does not allow for interference check Die was tooled and part edge was formed with a curl in it

32 2D VS 3D Interference check is shown with a bold RED line 3D model allows for these checks Which is more expensive a designer s time or a die maker s time? Can anyone afford avoidable rework?

33 Die Motion Simulation 3D Collision detection True timed motion Does the pilot enter first? Does the strip clear when lifted? Does the stripper plate have enough stroke? Does it over travel punches?

34 Thank You! Website: Phone: David s dlindemann@cimatrontech.com Cimatron info@cimatrontech.com

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