Shulou(Shulou.com)06/02 Report--

Research and development background

With the increase of the development density of new models in the automobile manufacturing industry, domestic automobile panel moulds urgently need to improve the level of research and development and manufacturing to solve the problems of insufficient capacity and long production cycle. There are many technical problems in the design and manufacture of automobile panel dies because of their large volume, complex structure and high technical requirements. how to design and manufacture high-quality stamping parts in a short time is a problem that stamping panel die enterprises must solve.

Huatian software SINOVATION provides a complete solution for the design and manufacture of automotive panel dies. Based on the background of Japanese automobile manufacturing industry and Japanese experience in stamping die design and manufacturing, Huatian software provides specialized solutions for the whole process from stamping process design, springback compensation, structure design, structure inspection to die processing, FMC machining, laser cutting and NAVI dynamic design navigation system for knowledge accumulation.

Fig. 1 solution for design and manufacture of SINOVATION stamping die

In China, because many enterprises are still using NX, CATIA and other design software for mold research and development, there is no solution in some links, which leads to the use of common modeling functions for design, which greatly reduces work efficiency and causes waste to production arrangements. for example, some enterprises have to debug the springback compensation of stamping parts several times or more. Only this rebound and debugging has caused a great waste to the enterprise in terms of people, property and cycle. In the mold CAD model to CAM processing link, in order to avoid, the mold part of the fillet will be made small, in these design software can only be done by hand, resulting in low efficiency, the use of labor intensity.

In order to further strengthen the mold solution of SINOVATION, provide users with more efficient design and manufacturing tools, improve efficiency and reduce costs, Huatian Software conducts meticulous development by investigating the front-line needs of Dongfeng Mould, Jianghuai Mould and other enterprises to solve users' practical problems.

Development content

1. Accurate stamping springback compensation

With the increasing frequency of high-strength sheet metal, the springback phenomenon of stamping deformation has become a common defect in the process of sheet metal forming. Springback deformation seriously affects the correctness and accuracy of die design. Therefore, if we want to get the shape that meets the design requirements of the part, we must change the shape of the mold surface. General CAD software does not provide springback compensation for the mold surface, so users can only use basic functions to adjust it little by little.

Huatian Software has developed a springback supplementary processing method for a variety of scene scenes in SINOVATION, such as directly based on distance and angle, based on analysis results and based on workshop measurement data.

1.1 springback compensation based on distance and Angle

Modify the surface based on the distance or angle values of points, lines, and other objects, which can be measured or empirical values. The SINOVATION [Global precise deformation] command can drive the surface deformation according to the displacement between the original object and the target object, so as to quickly make a springback compensation surface.

Fig. 2 springback modified by the displacement of points and lines

Fig. 3 springback modified by three-coordinate scanning points

Figure 4 modify springback by angular rotation

1.2 springback compensation solution based on physical measurement

During the pressure test and debugging in the workshop, the user will generally sample the stamping results in three coordinates or using white light scanning to adjust and obtain the correct mold shape. SINOVATION has developed the function of springback compensation based on the measured data of three-coordinate or white light scanning.

Figure 5 modify springback by measuring data

1.3 springback compensation solution based on FEA-MESH

Most users use forming analysis software such as AutoFORM and Dynaform for process analysis, and users hope to use the FEA results in this kind of software to adjust the digital model in CAD. Accordingly, we develop a springback compensation function based on FEA results, which can automatically drive the surface deformation according to the change of the pre-and post-springback mesh obtained by CAE analysis, generate the springback compensation surface and maintain the same topology as the original surface model. Users no longer have to spend a lot of time manually rebuilding the surface after springback compensation.

Figure 6 modify springback through CAE analysis data

1.4 advantages of SINOVATION springback compensation:

SINOVATION in the stamping springback compensation solution has been applied in Jianghuai Fuzhen, Qiruihu, Chongqing digital mold and other domestic well-known mold enterprises, so as to provide efficient design and manufacturing tools for the mold industry, and solve the bottleneck problem that has plagued enterprises for a long time.

Fig. 7 Analysis of SIONVATION springback advantage

2. Gap design

Gap design technology (deviation processing technology) originates from Toyota mold in Japan. Toyota has a unique "quality assurance drawing (gap design drawing)" to guide fitters' mold closing and debugging. After the numerical control machining of Toyota, after a simple correction by fitters, the qualified rate of the test parts of the press for the first time reached an astonishing 85%. What plays the greatest role during this period is the gap design technology, also known as deviation processing technology. Generally, the digital surface of the automobile body sheet metal parts is processed before NC machining, such as the actual profile area of the die, the gap value of each area, the change of the die surface required by the process, the change of the drawing fillet, the hollowing out of various die surfaces, etc., on the premise of not affecting the die performance, reduce the mold processing and lapping time, improve the production efficiency and reduce the production cost. Because the current practice, whether through the programmer to edit and adjust the processing program, or the mold surface with the help of a variety of software manual processing, or the follow-up fitter self-dressing, will spend more time and energy. If the software is used for better automatic processing, it can effectively reduce the mold lapping time, reduce the labor intensity of fitters, improve production efficiency and reduce production costs.

Therefore, with the support of die and mould enterprises, Huatian Software has developed some functions on SINOVATION, such as concave fillet reduction treatment, concave die uplift treatment, blank holder ring management surface strong pressure treatment, material core pressure zone treatment, concave fillet enlargement treatment, convexity removal and easy interference surface treatment, sidewall air opening treatment and so on, in order to accelerate the efficiency of die design.

Fig. 8 SINOVATION gap design

If you want to avoid the concave R part of the die surface before processing is a very time-consuming and laborious work, most of the software can only rely on manual processing of a fillet and a fillet, which can be imagined for the complex digital simulation workload of automobile panels. The solution developed in SINOVATION solves the problem of rapid retrieval and automatic processing, which greatly improves the efficiency of profile modification; it takes 8 hours to use general CAD and can be completed in less than 30 minutes in SINOVATION. A user verified the function of the mold in production as follows: through the automatic retrieval of the concave R angle, 1219 fillets were retrieved, and through the reduction command of the concave R angle, the successful modification rate reached 76%, but the whole process only took a few minutes.

Fig. 9 SIONVATION concave R advantage analysis

Fig. 10 SIONVATION concave R advantage analysis

The value it brings to customers

Through the fine research and development of automobile panel die design and manufacturing by SINOVATION software, not only the international high-level die design and manufacturing experience is brought to domestic customers, but also it is of great significance to solve the problems of poor formability and low precision in domestic automobile panel manufacturing. Huatian Software will continue to pay attention to the technological development of domestic mold enterprises and promote the independent innovation of domestic mold enterprises.

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