Systematic Process Improvement

The sheet metal forming process is becoming more and more complex due to the ever increasing number of different car models, the geometric complexity of stamped parts as well as the widespread applications of high-strength steels and aluminum. In light of increased global competition, car manufacturers aim to deliver high quality stamped parts using state-of-the-art technologies which allow for a lower lead time. To address these challenges, AutoForm Engineering has developed an innovative approach to the systematic improvement of the sheet metal forming process. This approach enables engineers to systematically improve the sheet metal forming process already in the early engineering stage.

AutoForm’s Systematic Process Improvement brings deeper insight and transparency to the forming process by identifying which design parameters influence part quality and to what extent. Design parameters are those input parameters which can be adapted in part, tool and process design such as part radii, binder surface geometry, addendum geometry, use and position of drawbeads, blankholder force, lubrication, etc. Multiple stamping simulations are carried out automatically. During these simulations, design parameters are varied while engineers maintain their focus on the quality targets set for the stamped part. The quality target can be specified with regard to one or more output variables from the simulation, e.g. no splits, no wrinkles or sufficient stretching. In this way, design parameters which have the most influence on the stamped part can be identified already during the early engineering stage. Engineers can then make the necessary adjustments to the design parameters and simultaneously follow the effects these changes have on the entire part by viewing them on the computer screen. This procedure results in the systematic improvement of the forming process.

In Systematic Process Improvement, the best selected set of design variable values results in the most feasible process. It enables engineers to successfully deal with complex part geometry, high-strength materials and aluminum, tight deadline requirements as well as high quality demands. Through the better understanding of the forming process, shorter development times are achieved. By implementing Systematic Process Improvement, engineers can address and solve key manufacturing problems before going into production.

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AutoForm-Sigma – Software for Systematic Process Improvement during Process Engineering

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Robust Process Improvement

Customer Use Case:

Making its Mark

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