Sheet Metal Forming Simulation
Case Studies

Die Engineering Tests Tool Design Prior to Fabrication

Die Engineering (Brisbane, QLD, Australia) uses StampingSimulation's virtual tryout and simulation services to make process and tool design choices before committing to the final tool build. Simulating prior to beginning the tooling stage often yields significant savings in time and cost on the shop floor, and this job was no exception.

"During the first tryout, my customer's eyeballs almost jumped out his head when he saw we had made an acceptable part, so easily and quickly, with only minor adjustments to draw pressure." - Paul Elliston, Die Engineering Director

Simulation Videos

Figure 1: Part Geometry
It was found that, with simulation,  "traditional" methods for forming this type of part were predicted to cause severe wrinkles and splits. Using AutoForm's powerful sheet metal forming simulation tools, numerous process methods were simulated and an acceptable solution was engineered.

Figure 2: Actual part from tool at first tryout
The tool produced an acceptable part during the first tryout, with the only adjustment being cushion pressure to control metal flow.

Figure 3: Actual Tool
The engineered process was proven with simulation, showing that a single stage form would produce an acceptable part. Other methods (e.g., form and wipe) would have produced unacceptable wrinkles and splits, which would not have been discovered until the tool was built.

Figure 4: Simulation Result
Engineering the tool with simulation avoided a costly surprise at tryout that could have caused weeks of re-work, possibly requiring a completely new tool.