Die Engineering Pty Ltd (Die Engineering), a regular StampingSimulation.com customer, needed to be sure that a particular 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 wrinkling in the metal.
It was not possible to produce a wrinkle-free part from a normal forming or wiping process with a developed blank. Simulation determined that the part needed to be deep drawn with open ends and then re-trimmed. This fact alone saved tool build cost and tryout time. 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 an 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 three or four 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 be confident in the quality of the manufacturing process.” - Paul Elliston, Die Engineering
Figure 1: 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.
Figure 2: Thinning
The thinning plot shows the areas predicted to be thinnest during the draw process as well as which areas may thicken. The predicted splits are also clear.
Figures 3, 4, 5, 6, 7: 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.