Sheet Metal Stamping Simulation

Die Engineering 9520

• Forming Simulation
• Thining
• Actual Part
• Actual Part
• Actual Part
• Actual Part
• Actual Part
• Simulation Videos

Case Study Overview

Die Engineering Pty Ltd, a regular StampingSimulation customer, needed to be sure that this part could be formed successfully. Earlier prototype parts had been made with unacceptable wrinkles and it was the job of simulation to determine how to make this part without severe wrinkles.

Simulation determined that the part must be deep drawn, with open ends, and then re-trimmed. It was not possible to product a wrinkle free part from an normal forming or wiping process, with a developed blank. This fact alone saved massive amounts of tool build cost and tryout time, had the part been processed the wrong way. Furthermore, simulation showed the final forming station would split the final forms, and radius increase was required to avoid splits.

Using the simulation results, acceptable parts were made at first tool tryout with no adjustment other than increasing binder pressure to get optimum draw result.

“We determined that a basic form and flange process, from a developed blank for this part would result in severe wrinkles. Using simulation, we assessed 3 or 4 different ideas and in just a few days of simulation work we determined that a draw was necessary. This gave us the confidence to make the tools, knowing that we could make a successful part”
Paul Elliston, Die Engineering

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  Back to Top Forming Simulation

  The simulation result showed that the 2x emboss features, to be formed last, would split if original product radii were used. The solution was to increase the radii and the correct radii was determined with simulation.

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  Back to Top Thining

  The thinning plot shows the areas predicted to be thinnest during the draw process and which areas may thicken. The predicted splits are also clear.

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  Back to Top Actual Part

  The actual part avoided splits and avoided severe wrinkles, by using  sheet metal forming technology. Acceptable parts were made, after an increase in binder pressure, to match the simulation.

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  Back to Top Actual Part

  The actual part avoided splits and avoided severe wrinkles, by using  sheet metal forming technology. Acceptable parts were made, after an increase in binder pressure, to match the simulation.

• 

  Back to Top Actual Part

  The actual part avoided splits and avoided severe wrinkles, by using  sheet metal forming technology. Acceptable parts were made, after an increase in binder pressure, to match the simulation.

• 

  Back to Top Actual Part

  The actual part avoided splits and avoided severe wrinkles, by using  sheet metal forming technology. Acceptable parts were made, after an increase in binder pressure, to match the simulation.

• 

  Back to Top Actual Part

  The actual part avoided splits and avoided severe wrinkles, by using  sheet metal forming technology. Acceptable parts were made, after an increase in binder pressure, to match the simulation.

• Back to Top Simulation Videos