AutoForm Robustness Solution
Software Solution for
Maximum Stamping Robustness
Improving the robustness
of sheet metal products and processes is a key factor for
everyone in the sheet metal industry. Today, almost every
stamping company is faced with production problems that seem
to be random or unavoidable. |
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After stamping thousands of
parts that meet quality specifications, the reject rate suddenly
rises; for example after changing coils, it becomes impossible
to meet part quality tolerances |
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Missed production targets due
to the need to continually adjust the stamping process; for
example slight changes in press parameters (e.g. lubricant,
blankholder forces) or in product features (e.g. rounder
edges) cause an unstable stamping process |
The AutoForm Robustness Solution allows companies to address stamping
robustness issues during earlier phases of product and tooling design.
In other words, companies can now develop the best product designs
and the best tool designs for a robust stamping process.
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The software uniquely combines
statistical process control techniques with sheet metal forming
simulation. This allows engineers to determine the process
capability of stamping operations even during the earlier
phases of product and tooling design. As a result, unplanned
down-time and the trouble-shooting of press lines will be
minimized. |
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Variability and noise, which
are inherent in the stamping process, are taken into
account in the simulation, thereby better reflecting manufacturing
reality. Their influence on stamping process robustness is
quantifiable and predictable due to the combination of advanced
stamping simulation techniques and stochastic integrated
into the software. |
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The software identifies the
dominant factor that has the strongest effect on a quality
target. The multiple stamping simulations are carried out,
changing design and process parameters and performing statistical
analyses, until the “robust optimum” is found.
This robust optimum corresponds to the most reliable overall
conditions for stamping parts that meet a company’s
quality and production targets. |
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Appropriate statistical algorithms
have been selected and integrated in order for them to be
used directly by designers and stamping engineers, thus reducing
the workload on statistical analysis experts. This enables
concurrent engineering projects between product design, tooling
design and stamping production departments. |
Potential stamping problems can be solved earlier in the vehicle
development cycle by using the AutoForm Robustness Solution – saving
time and resources. This also means faster time-to-market
for new car models, with obvious advantages.
The main features of the AutoForm Robustness Solution include:
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Unique combination of statistical
process control techniques with forming simulation |
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Graphical set-up of design parameters
and noise variables |
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Rapid identification of variability
and noise influences on part quality |
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Automatic set-up and analysis
of multiple simulations |
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Graphical display of process
capability indicators (Cp and Cpk) directly on the part |
Application Examples:
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