stamping die solution overview updated 01142011

8/11/2019 Stamping Die Solution Overview Updated 01142011

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Page 1 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved

Stamping Die Development

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved


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The Siemens Solution

A single system covering the entire die development process

No information lost in data translation, or time wasted in repair

Low IT costs (purchase, training, deployment)


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Outline -- Die Development Framework

DiePlanning PartProductionPartDesign Try-OutDieFeasibility Die design &Validation DieManufacturing

ProductData

FormabilityAnalysis

SpringbackAnalysis

DieStructureAnalysis

Inspection

DesignCorrection

PartProduction

DieKinematicsValidation

PressLine

Optim.

PartTransferOptim.

DieLayout

PrimaryTry-out

SecondaryTry-out

DFMAnalysis

SpringbackModeling

Die StructureDesign

NCPreparation

Die FaceDesign

Die FaceMachining

2DMachining


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ProductData

FormabilityAnalysis

SpringbackAnalysis


Inspection

DesignCorrection

PartProduction


PressLine

Optim.

PartTransferOptim.

DieLayout

PrimaryTry-out

DiePlanning PartProductionPartDesign DieFeasibility Die design &Validation DieManufacturing

SecondaryTry-out

DFMAnalysis

SpringbackModeling

Die StructureDesign

NCPreparation

Die FaceDesign

Die FaceMachining

2DMachining

Try-Out


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Part Design

Current Capabilities

Part designed in NX or other CADsystems

Many ways to import product data(JT, IGES, STEP, etc.)

Extensive data quality checkingand healing functions Tolerance adjustment

Remove tiny edges

Remove tiny faces

Detect sliver faces

Detect spikes and cuts

Customer Benefits

No data translation (if part designed in NX)

Easy import from other systems

Checking Tools

Part Design


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Design-for-Manufacturing (DFM) Analysis


Checks the manufacturability of a panelduring the design stage

Verifies draw, trim, pierce, and flangecriteria based on corporate standards

Feedback saved in part file for review byproduct designers

The checks are available in Checkmate andDie Engineering

Customer Value

Reduces checking effort

Identifies problems early, so reducesrework in downstream processes

Trim Surface Angle Check


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ProductData

FormabilityAnalysis

SpringbackAnalysis


Inspection

DesignCorrection

PartProduction


PressLine

Optim.

PartTransferOptim.

DieLayout

PrimaryTry-out


SecondaryTry-out

DFMAnalysis

SpringbackModeling

Die StructureDesign

NCPreparation

Die FaceDesign

Die FaceMachining

2DMachining

Try-Out



Die Planning - LayoutCurrent Capabilities in NX

Generates complete Die Operation Lineup (DOL) takingmanufacturing processing rules into account.

Built-in manufacturing process knowledge helps makedecisions about Number of stations needed

Tipping angle of part

Type of cams and cam drives needed Filling open areas (holes, cut-outs)

Dynamic draft and depth analysis

The operations are created in multiple part files asneeded

Option in trim task to allow retaining the scrap shape asa sheet body for downstream scrap shed simulation

Customer Value

Visual display of manufacturing stages helps speed up

decision making Associative links speed up response to product changes

Filling

Trimming

Flanging


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ProductData

FormabilityAnalysis

SpringbackAnalysis


Inspection

DesignCorrection

PartProduction


PressLine

Optim.

PartTransferOptim.

DieLayout

PrimaryTry-out


SecondaryTry-out

DFMAnalysis

SpringbackModeling

Die StructureDesign

NCPreparation

Die FaceDesign

Die FaceMachining

2DMachining

Try-Out



Binder & Addendum Modeling

Current Capabilities in NX

Create binder wrap Create developable surface representing

shape of sheet metal after binder closes

Creation of planar, cylindrical and conical type of

surfaces through mono-arc

Addendum sections

Create sections to define the addendum Parameters available for editing

Shape conforms to given constraints

Access to the standard sections through reuse library

Addendum surface Create addendum surface based sections

Die Output Curves

Create accurate trim line

Draw Bead Specialized functions to create beads

Access to the standard sections through reuse library

Customer Value

Specialized modeling tools allow rapidconstruction of Die Face

Binder Creation

Plus

Punch Radius

Stretch Wall

Reverse Radius

Flat to Bead

Part

Addendum

BinderAddendum Section

After Convert to Flat Arcprocessing

Access to Reuse Library



One-Step Formability Analysis

Capabilities in NX Quick early analysis of formability

Flatten sheet metal to a blank

All within NX -- no data translation

Shows thinning, stress, and strain

Predict springback and generateanalysis report

Associative to the product model

The springback results are directly fed todie face deformation to compensate for

springback

Customer Value

Helps to reduce physical try-outs

Quick results allow iterative improvement

Thinning results

Stress results



Connections to 3rdParty Solvers

ETA provides two products: Dynaform, which allows NX part files to be

opened directly without translation, and BSE in NX, which allows one step

analysis to be invoked directly from within NX.

Autoform offers the Autoform in UG product that is fully integrated in NX. Die

Engineering users may invoke the one-step or incremental analysis functions

directly from NX.

The results from Autoform (mesh data) can be directly used for global

morphing within NX (e.g. to accommodate die panel for springback)

Engineering Technology Associates

Autoform Inc.

Die Data from NX can be transferred to Pamstamp through IGES or STEP

Pamstamp
http://www.esi-group.com/



Capabilities in NX

Several surface deformation functionsto compensate for springback. Global Deformation

Overcrown to Point

Overcrown to Curve(s) Wall Deformation

Flange Rotation

Match to Sheet

Radius Reduction

Customer Value

Specialised functions reduce the need fortime-consuming manual modeling methods

Maintains the original topology of thegeometries

Springback Compensation

Overcrown

Compensation to FE Mesh

Wall Deformation tomultiple target Curves

Radius Reduction



Die Face Modification(e.g. Springback Comp.)

OverCrown Area

Overcrown Color Map

Original

Deformed

Original

Deformed

Wall Deformation Radius Reduction

Original

Deformed



Radius Reduction

Capabilities in NX

Improved process workflow for radius reduction

Analyze the faces that fall within a user-

specified range of radius values.

The faces that are found may be assigned a

color or other attribute to allow easy selection

in other commands that request faces asinput.

The faces appear concave with respect to the

draw direction

The system select the faces automatically

based on the attributes and apply thereduction with the given percentage value

Customer Value

Eliminate the need for manual method of

preparing geometries for the radius reduction Improved productivity

Radius Reduction

Workflow


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ProductData

FormabilityAnalysis

SpringbackAnalysis


Inspection

DesignCorrection

PartProduction


PressLine

Optim.

PartTransferOptim.

DieLayout

PrimaryTry-out


SecondaryTry-out

DFMAnalysis

SpringbackModeling

Die StructureDesign

NCPreparation

Die FaceDesign

Die FaceMachining

2DMachining

Try-Out


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Die Structure Analysis

Capabilities in NX

Predict stress/strain/deflectionunder the given forming load

Optimize die structures withadequate stiffness evaluation

Customer Value

Helps reduce die weight

Allows study of alternativematerials for production dies


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Die Kinematics Validation

Capabilities in NX

Check die assemblies for interference

Simulation includes press, die, and part

Cross bar, tri-axis and transfer pressmodels are supported

Tracking curve generation

Associative links to die design

Customer Value

Reduces the need for physical tryout

for the die sets in the target press line. Integration with die design reduces

tedious data preparation work

Simulation can be performed earlyin the planning stage

Collision Check During Simulation

Die Inner Collision and Interference Check


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ProductData

FormabilityAnalysis

SpringbackAnalysis


Inspection

DesignCorrection

PartProduction


PressLine

Optim.

PartTransferOptim.

DieLayout

PrimaryTry-out


SecondaryTry-out

DFMAnalysis

SpringbackModeling

Die StructureDesign

NCPreparation

Die FaceDesign

Die FaceMachining

2DMachining

Try-Out


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NC Preparation

Current Capability

Synchronous Technology

Radius reduction

Surface extension

Filling holes

Composite curves

Many offsetting functions

And much more

Customer Value

Modeling tools readilywithin the same system

Associativity preserved

Synchronous Technology

Radius Reduction

Editing

without

history

Theoretical cornerHole Fill


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General NX CAM Capabilities

Current Capability

Broad capabilities in one system 2D machining for die structure

3D machining for die face

Associative links to design

Rich automation capabilities

Rich modeling capabilitiesavailable for NC prep work

Highly realistic simulation

Customer Value

One systemno data transfers

Associativity reduces rework effort

Automation reduces work, improvesstandardization and process stability


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2D Machining (Milling and Drilling)

Current Capability

Roughing -- cavity & pocket milling

Finishing -- planar, face, plunge milling

Drilling (manual or feature-based) holes

Automation based on machining knowledgedatabase, features, attributes, PMI

General Features In-Process Workpiece (IPW)

Tool path Editor

Toolpath verification

Customer Value

Automation reduces work, improvesstandardization and process stability

Planar Milling

Profile Milling


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3D Machining (Die Face Machining)

Current Capability Roughing

Z-Level Roughing

Gap Machining

Finishing

Contouring

Flow Cut

3D Profiling

Streamline

General Features

Surface region (steep/none steep)

IPW based rest material machining

High Speed Machining

Holder recognition & collision avoidance

Synch point distribution

Customer Value

Shorter lead-time to start of machining

Longer tool life

Automated rest material recognitionfaster

programming and machining Synchronized point distribution for better finish

Surface Machining


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Streamline-Based Finishing

Capability in NX

Streamline finishing pattern flowsnaturally with part shape

Not constrained by surface topology

Customer Benefits

Excellent surface finishfewersecondary clean-up operations required

Faster/easier programming

Streamline finishing

Traditional finishing


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Feature Based 2.5D Machining

Feature Recognition

+ PMI Data read

PMI data and features readdirectly from 3D model

PMI data attached to

NX solid model

Cutting

Tool

Library

Advanced PMI driven

machining system

Automatic

Programming Engine

Machining

Knowledge

Database

?

?

?

?

?

Step 1

Step 2

Step 3

Step 4

Finishing step

Stock

Operations

PMI data influences theselection of appropriate

machining process elements


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Machining simulation inside NX

Connection to controller logic makes simulation more realistic Accurate detection of collisions and machine limit violations

Accurate prediction of cycle times

Integrated Controller Driven Simulation

Siemens Virtual NC

Controller Kernel

SinumerikVNCK

NX CAM

Characteristics of

real controller Highly realistic

simulation

Increasing fidelity of simulation

Image


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Synchronized Point Distribution

Out of step points on

adjacent passes

Synchronized Point Distribution -

machine motion is consistent

for adjacent passesImproved

surface

finish

Synchronized point distribution improves surface finish


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ProductData

FormabilityAnalysis

SpringbackAnalysis


Inspection

DesignCorrection

PartProduction


PressLine

Optim.

PartTransferOptim.

DieLayout

PrimaryTry-out

DiePlanning PartProductionPartDesign Try-OutDieFeasibility Die design &Validation DieManufacturing

SecondaryTry-out

DFMAnalysis

SpringbackModeling

Die StructureDesign

NCPreparation

Die FaceDesign

Die FaceMachining

2DMachining


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Design Correction Process

Two possible approaches

Machine point cloud (facets)

Machine surfaces

Use approach #1 when Point cloud is dense

Part has no small details No modifications needed

Use approach #2 when Die Face and Die structure Design

required to maintain the changes

being made at the manufacturing

Required to machine the die faceand Die Structure Design

CompensatedFacet Data Compensate

facet data

GlobalDeformation

Clean uppoint cloud

Point cloud

CompensatedSurfaces

Inspection(scanning)Try-out

Die FaceMachining

Atos

Steinbichler

Cognitens

Remove noiseFill holes


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ProductData

FormabilityAnalysis

SpringbackAnalysis


Inspection

DesignCorrection

PartProduction


PressLine

Optim.

PartTransferOptim.

DieLayout

PrimaryTry-out


SecondaryTry-out

DFMAnalysis

SpringbackModeling

Die StructureDesign

NCPreparation

Die FaceDesign

Die FaceMachining

2DMachining

Try-Out


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Press Line Simulation (PLS)


User specific virtual presslines

Off-line programming capabilities

Die validation and collision check

Simulations include Part behavior during transfers Clearance & interference

Die check, assembly volume

Dynamic force calculations

Automatic tooling placement

Customer Benefits

Discover problems earlier

Reduce try-out time

Reduced space requirements

Increased stroke rates

Blanking line

Press line

Roll feeder

Cutting press

Feeder

Transfer

Press


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Die Duplication Process

Die Duplication often neededfor replication or repair

Two possible approachesMachine point cloud (facets)

Machine surfaces

Use approach #1when Point cloud is dense

Part has no small details

No modifications needed

Use approach #2 when Point cloud not dense enough

Part has small details notcaptured well in point cloud

Modifications needed

Facet Data Cleaned upfacet data

NX RapidSurfacing

Clean uppoint cloud

Point cloud

Surfaces

Scan originaldie face

Die FaceMachining

Atos

Steinbichler

Cognitens

Remove noise

Fill holes

Facets


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Summary

We have solutions to support the entire process in one system

Our solutions have been proven in production usage

We continue to invest in development in this area

We are ready to partner with you to support your implementation


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Thank you!

www.siemens.com/plm

stamping die solution overview updated 01142011

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