Stamping-Die-Solution - Overview-Updated 01142011

Stamping Die Development
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Page 1
The Siemens Solution
 A single system covering the entire die development process

 No information lost in data translation, or time wasted in repair
 Low IT costs (purchase, training, deployment)
Page 2
Outline -- Die Development Framework
Part Die Die Die design & Die Try-Out Part
Design Planning Feasibility Validation Manufacturing Production
2D
Machining
Formability NC Primary Secondary

Analysis Preparation Try-out Try-out
Die Face
Machining
Product Die Die Face Press Part
Data Layout Design Inspection Line
Optim. Production
Die Structure Design

Design Correction
DFM Part Transfer Springback
Analysis Optim. Modeling
Springback Die Die

Analysis Structure Kinematics
Analysis Validation
Page 3
Part Die Die Die design & Die Part
Design Planning Feasibility Validation Manufacturing Try-Out Production
2D
Machining

Die Face
Machining
Optim. Production

Design Correction
Springback Die Die

Analysis Validation
Page 4
Part Design
Current Capabilities
 Part designed in NX or other CAD
systems
 Many ways to import product data
(JT, IGES, STEP, etc.)
 Extensive data quality checking
and healing functions Part Design
 Tolerance adjustment
 Remove tiny edges
 Remove tiny faces
 Detect sliver faces
 Detect spikes and cuts
Customer Benefits
Checking Tools
 No data translation (if part designed in NX)
 Easy import from other systems
Page 5
Design-for-Manufacturing (DFM) Analysis
 Checks the manufacturability of a panel
during the design stage
 Verifies draw, trim, pierce, and flange
criteria based on corporate standards
 Feedback saved in part file for review by
product designers
 The checks are available in Checkmate and
Die Engineering
Customer Value
 Reduces checking effort
Trim Surface Angle Check
 Identifies problems early, so reduces
rework in downstream processes
Page 6
2D
Machining

Die Face
Machining
Optim. Production

Design Correction
Springback Die Die

Analysis Validation
Page 7
Die Planning - Layout
Current Capabilities in NX
 Generates complete Die Operation Lineup (DOL) taking
manufacturing processing rules into account.
 Built-in manufacturing process knowledge helps make
decisions about
 Number of stations needed
 Tipping angle of part Filling
 Type of cams and cam drives needed
 Filling open areas (holes, cut-outs)
 Dynamic draft and depth analysis
 The operations are created in multiple part files as needed
 Option in trim task to allow retaining the scrap shape as a
sheet body for downstream scrap shed simulation
Trimming
Customer Value
 Visual display of manufacturing stages helps speed up
decision making
 Associative links speed up response to product changes
Flanging
Page 8
Part Transfer Optimization
 Simulation of the part motion from
de-stacking through removal
 Calculation of speeds & acceleration
 Dynamic collision detection
 Detection of suction cup problems
due to speed and acceleration
 Programming of handling devices
Customer Value
 Early detection of motion problems
 Improved cycle times
Page 9
2D
Machining

Die Face
Machining
Optim. Production

Design Correction
Springback Die Die

Analysis Validation
Page 10
Binder & Addendum Modeling
Current Capabilities in NX
Plus
 Create binder wrap Part Punch Radius
 Create developable surface representing
shape of sheet metal after binder closes
 Creation of planar, cylindrical and conical type of
Stretch Wall
surfaces through mono-arc
 Addendum sections
 Create sections to define the addendum Reverse Radius
Addendum
 Parameters available for editing
 Shape conforms to given constraints Flat to Bead
 Access to the standard sections through reuse library

Addendum Section Binder
 Addendum surface
 Create addendum surface based sections
 Die Output Curves
 Create accurate trim line
 Draw Bead
 Specialized functions to create beads After Convert to Flat Arc
processing
 Access to the standard sections through reuse library
Customer Value Binder Creation
 Specialized modeling tools allow rapid

construction of Die Face
Page 11 Access to Reuse Library
One-Step Formability Analysis
Capabilities in NX
 Quick early analysis of formability
 Flatten sheet metal to a blank
 All within NX -- no data translation
 Shows thinning, stress, and strain
 Predict springback and generate
analysis report
 Associative to the product model
Thinning results
 The springback results are directly fed to die
face deformation to compensate for
springback
Customer Value
 Helps to reduce physical try-outs
 Quick results allow iterative improvement
Stress results
Page 12
Connections to 3rd Party Solvers
Pamstamp
Die Data from NX can be transferred to Pamstamp through IGES or STEP
Engineering Technology Associates

ETA provides two products: Dynaform, which allows NX part files to be
opened directly without translation, and BSE in NX, which allows one step
analysis to be invoked directly from within NX.
Autoform Inc.
Autoform offers the Autoform in UG product that is fully integrated in NX.
Die Engineering users may invoke the one-step or incremental analysis
functions directly from NX.
The results from Autoform (mesh data) can be directly used for global
morphing within ©NX
Page 13
2009.(e.g. to accommodate
Siemens Product dieInc.panel
Lifecycle Management Software for springback)
All rights reserved
Springback Compensation
Capabilities in NX
 Several surface deformation functions
to compensate for springback.
 Global Deformation
 Overcrown to Point Overcrown
 Overcrown to Curve(s)
 Wall Deformation
 Flange Rotation
 Match to Sheet
 Radius Reduction
Customer Value Compensation to FE Mesh

Wall Deformation to
 Specialised functions reduce the need for multiple target Curves
time-consuming manual modeling methods
 Maintains the original topology of the
geometries
Radius Reduction
Page 14
Die Face Modification (e.g. Springback Comp.)
Overcrown Color Map
Original
Deformed
OverCrown Area
Wall Deformation Radius Reduction
Original Original
Deformed Deformed
Page 15
Radius Reduction
Capabilities in NX Workflow
 Improved process workflow for radius reduction
 Analyze the faces that fall within a user-
specified range of radius values.
 The faces that are found may be assigned a
color or other attribute to allow easy selection
in other commands that request faces as
input.
 The faces appear concave with respect to the
draw direction
 The system select the faces automatically
based on the attributes and apply the
reduction with the given percentage value
Customer Value Radius Reduction
 Eliminate the need for manual method of

preparing geometries for the radius reduction
Page16 Improved productivity
2D
Machining

Die Face
Machining
Optim. Production

Design Correction
Springback Die Die

Analysis Validation
Page 17
Capabilities in NX
 Solid modeling of all die structures –
draw, trim, and flange dies.
 Trim Steel Assistants creates components
needed for trim stage in one step
 Casting features created with few steps
 Adds necessary machining information to
the die structure model (planar, holes, etc.)
 New/revised dies created from the Completed Die Structure Design
existing die templates (NX WAVE)
 Libraries of standard parts
Customer Value
 Improves visualization & analysis --
allowing problems to be detected earlier
 Modeling of die structures in 3D reduces
the need for drawings for downstream
© 2009. Siemens Product Lifecycle Management SoftwareCasting
Inc. All features
rights reserved
Page 18
Die Structure Analysis
Capabilities in NX
 Predict stress/strain/deflection
under the given forming load
 Optimize die structures with
adequate stiffness evaluation
Customer Value
 Helps reduce die weight
 Allows study of alternative
materials for production dies
Page 19
Die Kinematics Validation
Capabilities in NX
 Check die assemblies for interference
 Simulation includes press, die, and part
 Cross bar, tri-axis and transfer press
models are supported
 Tracking curve generation
 Associative links to die design
Customer Value Collision Check During Simulation
 Reduces the need for physical tryout

for the die sets in the target press line.
 Integration with die design reduces
tedious data preparation work
 Simulation can be performed early
in the planning stage
Die Inner Collision and Interference Check

Page 20
2D
Machining

Die Face
Machining
Optim. Production

Design Correction
Springback Die Die

Analysis Validation
Page 21
NC Preparation
Current Capability
 Synchronous Technology Editing
without
 Radius reduction history
 Surface extension
Synchronous Technology
 Filling holes
 Composite curves
 Many offsetting functions
 And much more …
 Customer Value Radius Reduction
 Modeling tools readily

within the same system
 Associativity preserved
Hole Fill Theoretical corner
Page 22
General NX CAM Capabilities
Current Capability
 Broad capabilities in one system
 2½D machining for die structure
 3D machining for die face
 Associative links to design
 Rich automation capabilities
 Rich modeling capabilities
available for NC prep work
 Highly realistic simulation
Customer Value
 One system – no data transfers
 Associativity reduces rework effort
 Automation reduces work, improves
standardization and process stability
Page 23
2½D Machining (Milling and Drilling)
Planar Milling
Current Capability
 Roughing -- cavity & pocket milling
 Finishing -- planar, face, plunge milling
 Drilling (manual or feature-based) holes
 Automation based on machining knowledge
database, features, attributes, PMI
 General Features
 In-Process Workpiece (IPW)
 Tool path Editor
 Toolpath verification Profile Milling
Customer Value
 Automation reduces work, improves
standardization and process stability
Page 24
3D Machining (Die Face Machining)
Current Capability
 Roughing
 Z-Level Roughing
 Gap Machining
 Finishing
 Contouring
 Flow Cut
 3D Profiling
 Streamline
 General Features
 Surface region (steep/none steep)
 IPW based rest material machining
 High Speed Machining
 Holder recognition & collision avoidance
 Synch point distribution
Surface Machining
Customer Value
 Shorter lead-time to start of machining
 Longer tool life
 Automated rest material recognition  faster programming
and machining
 Synchronized point distribution for better finish
Page 25
Streamline-Based Finishing
Capability in NX
 Streamline finishing pattern flows
naturally with part shape
 Not constrained by surface topology
Traditional finishing
Customer Benefits
 Excellent surface finish – fewer
secondary clean-up operations required
 Faster/easier programming
Streamline finishing
Page 26
Feature Based 2.5D Machining
PMI data and features read

directly from 3D model
Feature Recognition
+ PMI Data read
PMI data influences the

selection of appropriate
PMI data attached to machining process elements
NX solid model
Advanced PMI driven

Stock
machining system
Machining ? 1
Step
Knowledge ? 2
Step
Cutting Database
Tool ? 3
Step
Library Automatic
? 4
Step
Programming Engine
?
Finishing step Operations
Page 27
Integrated Controller Driven Simulation
•Machining simulation inside NX
•Connection to controller logic makes simulation more realistic
•Accurate detection of collisions and machine limit violations
•Accurate prediction of cycle times
NX CAM
Sinumerik Image
VNCK
Characteristics of
real controller Siemens Virtual NC Highly realistic
Controller Kernel simulation
Increasing fidelity of simulation
Page 28
Synchronized Point Distribution
Synchronized point distribution improves surface finish
“Out of step” points on Synchronized Point Distribution -

adjacent passes Improved machine motion is consistent
surface for adjacent passes
finish
Page 29
Part Die Die Die design & Die Try-Out Part
Design Planning Feasibility Validation Manufacturing Production
2D
Machining

Die Face
Machining
Optim. Production

Design Correction
Springback Die Die

Analysis Validation
Page 30
Design Correction Process
 Two possible approaches

Atos
 Machine point cloud (facets) Try-out Inspection Steinbichler
 Machine surfaces (scanning)
Cognitens
Point cloud
 Use approach #1 when
 Point cloud is dense
 Part has no small details Remove noise Clean up
Fill holes point cloud
 No modifications needed
 Use approach #2 when

 Die Face and Die structure Design Compensated
Die Face Facet Data Compensate
required to maintain the changes
Machining facet data
being made at the manufacturing
 Required to machine the die face 
and Die Structure Design
Compensated
Surfaces Global
Deformation

Page 31
2D
Machining

Die Face
Machining
Optim. Production

Design Correction
Springback Die Die

Analysis Validation
Page 32
Press Line Simulation (PLS)
Blanking line
 User specific virtual presslines Roll feeder
 Off-line programming capabilities

 Die validation and collision check Cutting press
 Simulations include
 Part behavior during transfers
 Clearance & interference Press line
 Die check, assembly volume Transfer
 Dynamic force calculations
 Automatic tooling placement
Customer Benefits
 Discover problems earlier Feeder
Press
 Reduce try-out time
 Reduced space requirements
 Increased stroke rates
Page 33
Die Duplication Process
Atos
Scan original Steinbichler
 Die Duplication often needed die face
Cognitens
for replication or repair
Point cloud
 Two possible approaches
 Machine point cloud (facets)
Clean up Remove noise
 Machine surfaces point cloud Fill holes
 Use approach #1when
 Point cloud is dense Facets
 Part has no small details
 No modifications needed Die Face Facet Data Cleaned up
Machining facet data
 Use approach #2 when 
 Point cloud not dense enough
 Part has small details not
captured well in point cloud
 Modifications needed Surfaces NX Rapid
Surfacing

Page 34
Summary
 We have solutions to support the entire process in one system

 Our solutions have been proven in production usage
 We continue to invest in development in this area
 We are ready to partner with you to support your implementation
Page 35
Thank you!
www.siemens.com/plm
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved Siemens PLM Software

Stamping-Die-Solution - Overview-Updated 01142011

Uploaded by

Copyright:

Available Formats

You might also like

Stamping-Die-Solution - Overview-Updated 01142011

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Stamping-Die-Solution - Overview-Updated 01142011

Uploaded by

Copyright:

Available Formats

Stamping Die Development

 A single system covering the entire die development process

Formability NC Primary Secondary

Die Structure Design

Springback Die Die

Formability NC Primary Secondary

Die Structure Design

Springback Die Die

Formability NC Primary Secondary

Die Structure Design

Springback Die Die

Formability NC Primary Secondary

Die Structure Design

Springback Die Die

 Access to the standard sections through reuse library

Customer Value Binder Creation

 Specialized modeling tools allow rapid

Die Data from NX can be transferred to Pamstamp through IGES or STEP

Engineering Technology Associates

Customer Value Compensation to FE Mesh

Wall Deformation Radius Reduction

Customer Value Radius Reduction

 Eliminate the need for manual method of

Formability NC Primary Secondary

Die Structure Design

Springback Die Die

Customer Value Collision Check During Simulation

 Reduces the need for physical tryout

Die Inner Collision and Interference Check

Formability NC Primary Secondary

Die Structure Design

Springback Die Die

 Customer Value Radius Reduction

 Modeling tools readily

PMI data and features read

PMI data influences the

Advanced PMI driven

Increasing fidelity of simulation

“Out of step” points on Synchronized Point Distribution -

Formability NC Primary Secondary

Die Structure Design

Springback Die Die

 Two possible approaches

 Use approach #2 when

Formability NC Primary Secondary

Die Structure Design

Springback Die Die

 Off-line programming capabilities

 We have solutions to support the entire process in one system

You might also like