Sheet Metal Stamping Simulation

Die Engineering 9822

• Forming Limit Information
• Incremental Simulation
• Drawn Parts
• Drawn Parts
• Draw Tool in Press
• Simulation Videos

Case Study Overview

Die Engineering has introduced sheet metal forming simulation on all but the most simple tooling projects, to get ahead of the competition and avoid a slow death, like many local toolmakers in Australia have unfortunately suffered.The most recent success for Die Engineering and StampingSimulation.com was a deep drawn front bumper reinforcement for the next model Toyota Camry. The product design called for a 590MPa Tensile Strength Japanese steel and other toolmakers had quoted the part to be drawn in a minimum of two stages. Die Engineering was able to determine in less than 24 hours, with simulation, that the product was feasible with just one draw and used the simulation results to ensure they quoted the best price for a feasible tool. No guess work and no added “fat” which may have made their quotation uncompetitive.

Needless to say, Die Engineering won the job and proceeded with the tool design based on the simulations provided at quotation. To be successful in the press, it was critical to use simulation to “validate” the final tool design, a virtual tryout using StampingSimulation.com’s SimulateLite Service. In addition, a sample of 590MPa production material was sent for uni-axial tensile strain testing at ThyssenKrupp Steel Services (Detroit, MI, USA). The data from this test was available in less than 24 hours and fed into the simulation, to ensure the most accurate simulation result was realized.“It was critical for the timing and cost of the project that we make acceptable parts at first tool tryout. But since we had used simulation, we knew the required binder force and to use lubrication to make a successful part. We found that our first part split! Quickly, we checked our blank size on the shop floor and realized we had cut the trial blank larger than the simulation determined. So a simple blank size adjustment and we made acceptable parts during our first tool tryout, no splits and no wrinkles. The press operator (the customer) couldn’t believe his eyes.” Paul Elliston, Die Engineering Director.

It was estimated that at least 4 or 5 days was saved in the press by using simulation early in the project and by simulating the final tool design. In fact, the job would have been lost at quotation if it was not determined that the product was feasible in one draw. “We had to be quick with simulation at quotation, to avoid being dead in the press.” The total cost of simulation on this project was US$1,628 for a single stage draw development with final validation and material testing, using AutoForm-Incremental simulation provided by StampingSimulation.com Pty Ltd.

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  Back to Top Forming Limit Information

  AutoForm-Incremental simulation result showing Forming Limit Information.

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  Back to Top Incremental Simulation

  The AutoForm-Incremental simulation shows every step of the draw process, using tool design data.

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  Back to Top Drawn Parts

  Drawn parts produced at the first tool tryout.

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  Back to Top Drawn Parts

  Drawn parts produced at the first tool tryout.

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  Back to Top Draw Tool in Press

  Draw tool in press at the first tool tryout, with successful drawn part in the tool. 

• Back to Top Simulation Videos