siemens automotive stamping solutions
TRANSCRIPT
Manufacturing companies are now able to combine PLM software withSiemens production equipment to transform the design,manufactureand production efficiency of die engineering, press line commissioningand ramp-up.
Siemens automotivestamping solutions
www.siemens.com/plmSiemens PLM Software
Automotive stamping diesand press lines are high-cost, long lead-time investments.To maximize return on invest-ment (ROI), it’s important tostreamline development andcommissioning of new lines,while flexibly adapting existinglines to new designs.
Your fully functioning press line’sROI depends on the timerequired for die engineering,optimization, building and setup aswell as press line commissioningand production ramp-up. ROIalso depends on the press line’sthroughput while running inproduction. In addition, becauseof the complex nature oftoday’s press lines, the successof your stamping process isnever fully determined untilthe commissioning processis complete.
As you plan, design, validate,manufacture and commissionyour press line equipment, youcan leverage Siemens PLMSoftware’s complete suite ofCAD,CAM,CAE and PLMsolutions and Siemens productionequipment (which includescontrollers and drivers) to:
• Reduce the time needed forproduction ramp-up
• Achieve greater throughputwithout sacrificing quality
• Meet material waste reductionobjectives
Increase return on stamping dieand press line investments
Siemens automotive stamping solutions are used by leading companiesto optimize operational efficiency and reduce time, cost and errors indesign, planning and production of sheet metal parts and dies.
Best-in-class software applications and productionequipmentSiemens PLM Software provides a comprehensive and integratedfoundation of CAD/CAM/CAE/PLM applications for planning, designing,simulating and manufacturing complete stampingdie press lines.
Siemens SIMOTION controller and drives deliver stamping lineequipment that facilitates production reliability, intelligent energymanagement and maintenance cost reduction.
Complete and integrated solution set from planningto commissioningThe stamping process plays a major role in determining theefficiency of automotive body part production. Ever-increasingrequirements for shorter production times are met by leveragingSiemens PLM Software’s specialized planning, design, manufacturingand simulation solutions.
Process planning and data managementStamping process development is a highly collaborative activityrequiring effective communication across multiple disciplinesincluding product design, tooling design, manufacturing engineering,industrial operations and production teams. Siemens PLM Softwaresolutions provide process planning, data management andconfiguration control, as well as flexible reporting, to ensure theavailability of the right data, when and where it’s needed.
Introducing Siemens automotive stamping solutions
1
PROVEN VALUE
• Increase the stroke rate by 10 percent
• Reduce try-out time by 70 percent
• Reduce tooling design cost by 50 percent
• Reduce die design errors by 90 percent
Achievable improvements as reportedby customers.
Productdata
Dielayout
Die facedesign Inspection
Press lineoptimization
Primarytry-out
2Dmachining
Die facemachining
Secondarytry-out
Formabilityanalysis
NCpreparation
Partproduction
DFManalysis
Part transferoptimization
Springbackmodeling
Partdesign
PaPParParParParParParParParParaParPaParParPararttttttttttttttttddesdesdesdedesdesdesdesdesesdesdesdedesdesdesd sd signigngngngnignignignignignignignnignnigngg
Springbackanalysis
Die structureanalysis
Die structuredesign Design
correction
Die kinematicsvalidation
Dieplanning
Partdesign
Diefeasability
Die designand validation
Diemanufacturing
Partproduction
Try-out
2
Business value
Whether you need to improve a specific phase of die setdevelopment or optimize the entire integrated process chain,Siemens automotive stamping solutions are scalable and can beimplemented to your specific requirements.
Siemens automotive stamping solutions are designed to generateimmediate value for turnkey operations and press linemanufacturers while providing press line suppliers with a higherdegree of confidence in a proposed press system. In addition,these solutions deliver advantages to automotive OEMs, includinghigher return on capital investment, faster time to market andimproved plant productivity.
Increase speed to productionYou can shorten overall die engineering and press line commissioningtime by utilizing Siemens’ integrated applications for die designautomation, documentation, analysis, simulation, NC programmingand press line programming capabilities.
Maximize throughputYou can engineer the optimized combination of transfer motion andstroke rate. Siemens stamping die solutions interface the digitalmodel of the working press with the actual press controllersoftware to generate realistic motion curve data, calculate holdingforces for cups and grippers and eliminate potential bottleneckswhile optimizing overall throughput.
Part design Die planning Die feasability Die designand validation
Dieplanning
Partdesign
Diefeasability
Die designand validation
Diemanufacturing
Partproduction
Try-out
PROVEN VALUE
• Die design time reduced by 20percent
• Die modification time reduced by40 to 45 percent
• Reduction in modification costs
MUSCO Stamping, a division ofMahindra Ugine Steel Co.
3
Consistently achieve qualityYou can optimize and validate the full working design of press lineequipment long before it is built and installed. Siemens automotivestamping solutions enable engineers to eliminate design errors andmaintain a quality product by providing a full working digital modelof the press, its associated tooling equipment and behavior.
Boost productivity and reduce costYou can achieve significant gains in manufacturing productivity andcost reduction by re-using industry best practices to reduce errorsand rework. Siemens automotive stamping solutions are built withproven automotive stamping know-how and packaged into a set ofprocess-based applications streamlined to address the mostcomplicated die development projects.
Manage complexityYou can manage the data and processes associated with thestamping die design through commissioning process chain.Siemens automotive stamping solutions enable you to leverageproduct change, updates and dependencies throughout thedevelopment process, resulting in improved quality and ashortened time to production.
PROVEN VALUE
• Design time reduced by 50 percent
• Lower die costs
• Reduced rework
• NC programming time cut by 50percent
• Machining 30 percent faster
Rasandik Engineering Industries India LTD.
Die manufacturing Try-out Part production
Dieplanning
Partdesign
Diefeasability
Die designand validation
Diemanufacturing
Partproduction
Try-out
4
A vehicle’s body design and individual body panel parts not onlyinfluence the vehicle’s appearance, but also affect its overall safety,weight, and performance. Inner and outer body panel part modelsare the manufacturing team's primary input for initiating thestamping die development process, which requires a long lead-time.Since body design is crucial to most vehicles’ marketing success, it isnot uncommon for body panel designs to change often and late inthe vehicle development cycle due to evolving design, engineeringand manufacturing requirements.
Siemens PLM Software provides the design and modeling toolsfor quickly and effectively generating and editing complicatedautomotive body panel parts, and tools for working with dataimported from other CAD systems.
Quickly model accurate automotive sheet metal partsSupport of automotive workflows within a single system enablesmaximum efficiency and creative flexibility.
Easily update models to design changesDesign changes happen in real time by direct manipulation of themodel, without needing to understand the history of how themodel was created.
Document designs for proper manufacturingPMI (product manufacturing information) can be directly specifiedon the 3D model and used to create accurate, fully associativedetailed drawings. PMI can also be made accessible to the extendedenterprise/supply chain for manufacturing automation.
Part design
Advantages
Easily work with data from any CAD system by using dataquality checks, geometry healing, and an extensive set of datatranslators
Reduce design time by applying specialized sheet metalfeatures and Synchronous Technology for rapid model edits
Ensure proper manufacturability upfront during the designphase with comprehensive checks for draw, trim, pierce, andflange criteria
Automate checking of part designs for conformance tocorporate standards
Dieplanning
Partdesign
Diefeasability
Die designand validation
Diemanufacturing
Partproduction
Try-out
5
Die planning
The ROI of a press line is established during the early planningphases when die lineup and production throughput targets aredetermined. Die lineup spacing, opening height, and material travelspeed are all critical factors that directly impact the overallefficiency of the working press line and can influence the frequencyof maintenance interruptions and downtime.
Siemens PLM Software provides the complete set of tools fordefining the die operation lineup (DOL) and optimizing lineefficiency to help ensure planned production targets are achieved.
Rapidly layout the die lineupYou can generate process models for each station of the press line, aswell as determine which areas of the part should be formed, flangedand trimmed. In addition, you can determine the location of the holesand tip the part into the die position.
Optimization of die lineup efficiencyYou can leverage the PLM solution to calculate and simulate partmotion from de-stacking through removal.You can also calculatepart transfer speeds and application, as well as identify and correcthandling issues caused by part transfer speed and acceleration.
Part deflection/behavior simulationThe PLM die planning solution enables you to simulate materialdeflection of the part under transfer conditions as you plan the dieline's operational parameters. It also optimizes positioning ofholding devices like grippers, shovels and suction cups.You candefine clearance zones that account for part deflection underproduction conditions to aid die design and transfer programming.
Advantages
Leverage manufacturing process rules that enable you to makebetter manufacturing throughput decisions
Optimize the stamping position of parts using dynamic draft anddepth analysis
Improve collision detection accuracy by including workpiece andholding device deformation in part transfer clearance analyses
Validate suction cup and gripper holding force requirements perpart transfer speed and acceleration
Material deflection analysisTransfer motion analysis
Die operationlineup (DOL)
6
Ever increasing material prices and operational costs continue toamplify the value of eliminating physical try-outs. Companies thatare able to accurately produce desired stamping results with aminimum number of physical try-outs and prototypes gain anadvantage over their competition.
Siemens PLM Software's specialized design and analysis tools enableyou to quickly and virtually assess the feasibility of forming parts forhighly accurate die face designs.
Account for all details when designing the die faceYou can use these tools to produce a highly accurate digital modelof the sheet metal that accounts for draw, trim and flange elementsof the die process.You can create additional geometry needed inthe draw stage such as binder wraps, addendum die sections,addendum surfaces and beads.
Utilize formability considerations to increase accuracyDesign and analysis tools enable you to perform formabilityanalyses early in the design cycle and account for stress, strain,and thinning considerations.You can flatten the sheet metal partto a blank and automatically generate documentation andreports of the results of the formability analysis.
Compensate for springback to minimize physical try-outsYou can predict and compensate for springback by utilizing surfacedeformation functions for overcrown, overbend and walldeformation.
Die face design and feasibility
Advantages
Automate meshing of parts for formability analyses to save time
Perform formability analyses directly within the NX application
Speed the design of the die face by utilizing process-specificfeatures to create draw stage geometry
Dieplanning
Partdesign
Diefeasability
Die designand validation
Diemanufacturing
Partproduction
Try-out
Wall deformation
Die face design
Stress results
Thinning results
Overcrown
Die structure design and validation
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Die assemblies can be time-consuming and tedious to design dueto their complexity and inherently large number of components.Likewise, these same characteristics can make it difficult to achieveproper function and results during initial try-out.
Siemens PLM Software provides specialized automation tools toaccelerate the design process.These tools also ensure the deliveryof intended functionality via virtual try-out and simulation.
Automate design of the die structureYou can automate the design of die structures using a wide rangeof features for castings, trim steel and associated scrap cutters,flange steel, draw punch, upper draw die, lower binder, upper pad,owers post and steel inserts.
Analyze for structural strengthPLM solutions enable you to predict stress, strain, deflectionunder a given forming load and evaluate the die structure foradequate stiffness.
Validate operating conditions of the die set with simulationThese tools enable you to simulate the intended operation of thedie set and check for inner die interference/collision conditions.You can extend the life of the die by identifying and correcting camdrive malfunctions and improving functional efficiency.
Collision check duringSimulation
CAE
Advantages
Leverage kinematic simulations that include all components of thedie (press, die, part, transfer equipment) for more complete results
Easily visualize transfer clearances through the use of tracking curves
Rapidly analyze multiple design configurations using simulations thatare associative to the die design
Speed die structure design by leveraging an extensive library ofstandards parts
Automatically include machining information in your die structuremodels to accelerate NC programming
Capture and re-use proven die structure designs forfuture projects
Automotive industry expectations for delivery time, price, andquality continue to become increasingly demanding. Likewise,machine tools, materials and parts are becoming more complex.These factors can negatively impact manufacturing efficiency.As a result, they drive manufacturers to find new manufacturingapproaches for optimizing machining and eliminating waste.
Siemens PLM Software provides NC programming with advancedcapabilities, programming automation, and production ready outputto help optimize your machining operations by reducing machiningtime, eliminating errors and improving part quality.
Quickly prepare CAD models for NC programmingAn extensive set of modeling capabilities is available to NCprogrammers for model preparation including hole fill, radiusreduction, surface extension and surface offsetting.
Advanced programming capabilities for die face machiningA wide range of high-speed machining (HSM) strategies deliverefficient hard milling.The machining data library provides provendata for optimum machining performance. Synchronized pointdistribution delivers superior surface finish. NC programs areassociatively linked to design data for rapid updates to changes.
Automate programming of die structure componentsYou can save time by using feature based machining (FBM)capabilities to automatically recognize features and assign theproper machining operations.You can also increase efficiency bycapturing and re-using your proven machining processes.
Simulate machining to eliminate errors before productionYou can verify machining operations by using highly accurate anddigital machine tool models before heading into production to savetime, material and machine tool resources.
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Die manufacturing
Advantages
Employ proven machining strategies to reduce machining time byas much as 50 percent
Minimize the number of prove-outs with highly accuratemachining simulations
Achieve faster repeatable NC programming, requiring lessexpertise
Use programming automation to cut NC programming time
Use the same system for CAD/CAM to eliminate data translation
Dieplanning
Partdesign
Diefeasability
Die designand validation
Diemanufacturing
Partproduction
Try-out
Hole fill
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Regardless whether you’re commissioning a new line or modifyingan existing line, you need to meet your start-of-productiondeadlines, as well as your production throughput and qualitytargets.To achieve these objectives, you must be able to quicklyrespond when unacceptable try-out results occur, which requiresyou to have intimate knowledge of the entire press.
Siemens PLM Software's reverse engineering toolset enables youto support the activities associated with modifying, maintainingand repairing your press line equipment by ensuring that the partsyou manufacture are produced to the desired quality. In addition,you can employ Siemens PLM Software's press line simulationcapabilities prior to commissioning the press line to ensurethat it will run error-free at peak performance.
Rapidly correct the die face based on try-out resultsYou can directly machine corrections from the polygon data whenparts are small and lack details. Powerful modeling capabilities areavailable to enable you to rapidly generate surfaces from polygonswhen scan data is insufficient for machining.
Validate kinematics by simulating actual press lineoperating conditionsYou can simulate the intended operation of the press-line,individual press elements and inter-press handling equipment tocheck for interference/collision conditions.You can verify partbehavior with dynamic loading during transfers. Kinematicsimulations can include cross bar and tri-axis press types.
Optimize throughputYou can optimize throughput by simulating the entire press line.You can program the press directly from optimized simulationparameters based on the job and press parameters.
Try-out and optimization
Advantages
Ensure stamping process sustainability by feeding back data fromthe physical process to the virtual planning and designenvironment
Reduce ramp-up time by optimizing stroke rate and material flowin the virtual try-out phase
Use the virtual process planning phase to eliminate iterations andreduce physical try-out time on the shop floor
Use job-specific press setup information and try-out results toreduce the overall time to production
10
Die duplication and repairWhen minor changes to the production part or die repairs areneeded, dies can be easily reproduced and updated.The die facescan be machined directly from scanned polygon data or fromsurfaces developed from scanned data. Specialist partner TTLprovides NX CAM based adaptive machining for die face scanningand re-machining.
Virtually commission the pressYou can simulate the setup procedure and die change process toensure a collision-free setup environment.
Simulate part productionYou can execute a virtual production run using the actual controllerprogram data, complete the press model including the press line,die sets and part stages and transfer to verify a properly functioningproduction environment.
Directly transfer program data to the shop floorYou can transfer validated programming parameters and settings fromthe simulation environment directly to the actual press line controller.
Commissioning and part production
Advantages
Improve confidence while reducing time to production
Rapidly perform tool changes
Quickly adapt dies to design changes
Reduce downtime due to repairs and maintenance
Dieplanning
Partdesign
Diefeasability
Die designand validation
Diemanufacturing
Partproduction
Try-out
Data collection
Die duplication process
Data cleaning Surfacing Machining
11
New advances in press line technology at the servo drive levelenable you to flexibly control slide motion. Servo drives can deliverup to a 30 percent improvement in press throughput overconventional mechanical and hydraulic presses. But in order toobtain these benefits you need to precisely synchronize the motionof the slide and transfer system with the motion of the draw andstamping dies.
This level of motion optimization requires a sophisticated softwareenvironment that can drive a complete simulation of a virtual pressmodel by leveraging the actual press controller program. SiemensPLM Software’s press line simulation application can accomplishthis by reading and simulating actual press motion curves fromSIMOTION, Siemens’ motion control system for electronically-driven press lines.
In addition to improving production throughput, the directintegration of the press line simulation application and theSIMOTION controller facilitates:
• Virtual functional verification of the working press system
• Improved energy utilization
• Direct data exchange between the simulation software andthe press line controller
• Press line programming based on optimized controlprograms from the simulation output
Simulation assisted optimization of motion curves
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In today’s highly competitive automotive marketplace, industry-leading companies must effectively leverage the combined strengthsof their engineering and manufacturing teams to deliver world-classproducts.
Teamcenter® software’s capabilities for manufacturing processmanagement enable your product development and manufacturingoperations to collaborate and become more efficient acrossthe product lifecycle. By managing manufacturing data and process,resource, and plant knowledge in the same PLM environmentthat your use for product development,Teamcenter allowsyou to streamline new product development and launchprocesses to optimize your cost structures and satisfyestablished production goals.
Single source of manufacturing knowledge: Teamcenter provides asingle source of manufacturing knowledge that enables you torationalize and leverage your engineering assets and synchronizeyour manufacturing deliverables in a parallel workflow.
Advanced BOM/BOP management: Teamcenter associatively relatesessential bill of materials (BOM) information with yourmanufacturing bill of process (BOP).This ensures you are using theright product configurations in the right manufacturing context.
Production and shop floor management: Teamcenter’s tight integrationwith Tecnomatix® software enables your PLM environment toleverage manufacturing and production data from a complete suiteof digital manufacturing solutions.Teamcenter’s open serviceoriented architecture (SOA) integrates CAM, ERP and MESsystems-of-choice into your PLM environments.
Teamcenter provides standardized process templates andautomated work instructions to simplify the transfer of planninginformation to your shop floor.
Manufacturing resource visibility:With Teamcenter, you can classifymultiple manufacturing resources (tooling, fixtures, machinery androbots) and establish best practice processes to manage their use.Integrated tools enable you to mock up, visualize, analyze andoptimize plan layout and material flow.
Manufacturing process management
Advantages
Enable product and manufacturing teams to work in parallel,reducing planning time by 40 to 50 percent
Increase productivity and support lean manufacturing and design-for-manufacturing initiatives
Synchronize BOM and BOP activities to enable teams to betterunderstand product change
NX™ Software’s Body Design: Provides automotive designers andengineers with a tailored set of features, assistants and advisors forquick and simple creation and validation of body-in-white sheetmetal parts.
NX Die Engineering: Provides a process-specific toolset for laying outand planning the tasks to be performed in each station of the dielineup.Also includes specialized tools to assist in accelerating thedesign of die faces.
NX OneStep Formability: Provides a FEM-based sheet metalunforming, flattening and formability analysis solution for die makers.
NX Global Shaping: Includes a set of specialized functions to deformsheet metal parts and compensate for springback.
NX Die Structure Design: Provides a comprehensive toolset fordesigning complete die structure solid model assemblies thatincludes standard components for piercing equipment, pressuresystems and air cylinders, as well as specialized features for draw,trim and flange dies.
NX Die Validation: Enables die designers to simulate and check thefunction of die assemblies with respect to collision-free operationwithin the press.
NX Machining: Enables you to accelerate NC programming andimprove productivity for a variety of typical manufacturingchallenges, from basic machining to complex, multiple-axis andmulti-function machining, as well as for mold and die manufacturing.
Tecnomatix Press Line Simulation: Includes a comprehensive set ofprocess line programming, simulation and analysis tools that enableyou to digitally prepare and optimize key elements in a press linejob early in the planning phase.
Tecnomatix Part Planner: Enables manufacturing engineers, NCprogrammers, tool designers and managers to work in a managedenvironment with build-in applications for creating outline processplans, managing and associating tools and creating reports targetedat part manufacturing.
Resource Manager: Includes Teamcenter’s solution for managing awide range of manufacturing resource data, including everythingfrom cutting tools, machine tools and fixtures to robots, weldingguns and manufacturing process templates.
Manufacturing Process Management: Includes Teamcenter’s solutionfor enabling design and manufacturing teams to formally collaboratein a digital environment with full associativity between product,process, resource and plant information.
SIMOTION control system and SimoPress Servo drives: Provides anenergy efficient, fast and flexible servo press system for poweringthe most demanding press lines. Retro-fits to existing hydraulicand mechanical presses to further enhance productionperformance.
Siemens automotive stamping solutions
Productdata
Dielayout
Die facedesign Inspection
Press lineoptimization
Primarytry-out
2Dmachining
Die facemachining
Secondarytry-out
Formabilityanalysis
NCpreparation
Partproduction
DFManalysis
Part transferoptimization
Springbackmodeling
Partdesign
PaPParParParParParParParParParaParPaParParPararttttttttttttttttddesdesdesdedesdesdesdesdesesdesdesdedesdesdesd sd signigngngngnignignignignignignignnignnigngg
Springbackanalysis
Die structureanalysis
Die structuredesign Design
correction
Die kinematicsvalidation
Dieplanning
Partdesign
Diefeasability
Die designand validation
Diemanufacturing
Partproduction
Try-out
HeadquartersGranite Park One5800 Granite ParkwaySuite 600Plano, TX 75024USA972 987 3000Fax 972 987 3398
www.siemens.com/plm
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About Siemens PLM Software
Siemens PLM Software, a business unit of the Siemens IndustryAutomation Division, is a leading global provider of productlifecycle management (PLM) software and services with nearlysix million licensed seats and 56,000 customers worldwide.Headquartered in Plano, Texas, Siemens PLM Software workscollaboratively with companies to deliver open solutions thathelp them turn more ideas into successful products. For moreinformation on Siemens PLM Software products and services,visit www.siemens.com/plm.
Siemens PLM Software© 2009 Siemens Product Lifecycle ManagementSoftware Inc. All rights reserved. Siemens and theSiemens logo are registered trademarks of Siemens AG.Teamcenter, NX, Solid Edge, Tecnomatix, Parasolid,Femap, I-deas and Velocity Series are trademarksor registered trademarks of Siemens Product LifecycleManagement Software Inc. or its subsidiaries inthe United States and in other countries. All otherlogos, trademarks, registered trademarks or servicemarks used herein are the property of theirrespective holders.
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