Session : Blechumformung

Simulation in der Umformtechnik

Virtual
Virtual Conditioning
Conditioning of
of Progressive
Progressive Dies
Dies
Increasing
Increasing Productivity
Productivity and
and Quality
Quality

Erich Köhnert
Manager DIE Design Wört
TE, Automotive

TE Connectivity …

has a 50-plus year is a $14,3 billion

history of leadership company
(FY2011 Results)

AUTOMOTIVE

Customers

CONSUMER BROADBAND
CONNECTIVITY

is a global company ENERGY & has over 500,000

with nearly 100,000 INDUSTRIAL products
employees
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Session : Blechumformung
Simulation in der UMFORMTECHNIK

Automotive

Alternative
Power Systems Infotainment

Sensor
Technology

Wire and Tubing

Relays
Inductive
Systems

Terminals
Cable Assembly and
Systems Connectors

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TE Location Wört - Automotive

Stamping Wört

- High speed stamping

- Progressive Dies for

high volume production

~ 15 billion produced
parts in FY 2011

Stamping is a key technology within TE Connectivity

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 Session : Blechumformung
Simulation in der Umformtechnik

Presentation Topics

• Virtual conditioning

• Situation before Finite Element Analysis (FEA)

implementation

• Quality improvements by FEA

• Increasing productivity in tool shop by FEA

• Outlook

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Virtual Conditioning

What is Virtual Conditioning?

�To eliminate trial & error during fine tuning

�To simulate forming during die design phase

�To fix the proper blank profile at the first time

�To determine the right spring load

�To do feasibility studies w/o physical attempts

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Session : Blechumformung
Simulation in der UMFORMTECHNIK

Forming features at terminals & connectors

Insulation Area
Carrier Strip Wire Area

Transition

Transition

Contact Body

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Styles of Progression Dies

TE Stamping
Dies

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 Session : Blechumformung
Simulation in der Umformtechnik

Presentation Topics

• Virtual conditioning

• Situation before Finite Element Analysis (FEA)

implementation

• Quality improvements by FEA

• Increasing productivity in tool shop by FEA

• Outlook

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Before FEA

INPUT
In the past, many loops of
optimization were required to get
OK
the right result.
These approaches …
~ 6 – 20 weeks

- took much time not OK

- needed much rework
- caused high costs welding
- spent resources of toolmaker‘s grinding
labor filing
- permitted no reproducible polishing
processes testing
- bred a lot of discussions

OUTPUT
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Session : Blechumformung
Simulation in der UMFORMTECHNIK

Toolmaker

Conditioning is mainly performed by toolmakers and

by hand.

Adapting the
tool shape

Profiling by using
a file
Continuous
checking of form
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Situation in the Past

It was toolmaker‘s
work! (3D shape)

U-ing station
U-ing insert
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 Session : Blechumformung
Simulation in der Umformtechnik

Presentation Topics

• Virtual conditioning

• Situation before Finite Element Analysis (FEA)

implementation

• Quality improvements by FEA

• Increasing productivity in tool shop by FEA

• Outlook

Information is TE Confidential & Proprietary

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Results of Quality Improvement by FEA

After modification
lower damage
values

�no cracks.
Smooth surface

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Session : Blechumformung
Simulation in der UMFORMTECHNIK

Presentation Topics

• Virtual conditioning

• Situation before FEA implementation

• Quality improvements by FEA

• Increasing productivity in tool shop by FEA

• Outlook

Information is TE Confidential & Proprietary

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Determine Material Characteristics

Bending test
• Input from tensile
test: Rm, Rp02,
Epsilon, Youngs
modulus.
• Modifying material
properties
• Goal:
Angle(FEA)=
Angle(Bending
device)
• Modified material
properties for FEA
in 3D
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 Session : Blechumformung
Simulation in der Umformtechnik

Breakthrough Innovation by FEA

�������������������
����������������

����������������
First FE-trial to get
the shape of the Not 90�!
body area with given
layout

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Breakthrough Innovation by FEA

���������������

Rotate
Modified layout �����������������
by rotating
walls in CAD 90�!
and start
another
analysis with
FEA

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Session : Blechumformung
Simulation in der UMFORMTECHNIK

Increasing Productivity in Tool Shop by FE Analysis

Simulation
Potential

Zero
cond.

Future DIE Design & Part Assembly

FE-Analysis fabrication

FE-Analysis
Today DIE Design Part Assembly Conditioning
fabrication

Past DIE Design Part Assembly Conditioning

fabrication

Processing stages of a stamping die / Final Product

Idea Time to market

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•Divider
Thank you for your attention
Slide Title
 Session : Blechumformung
Simulation in der Umformtechnik

Info

• TE Connectivity, TE connectivity (Logo) are trademarks

• © 2012 Tyco Electronics

• www.te.com

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