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
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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.
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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
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Application Examples:
This product may practice one or more of the following patents
owned by or available to AutoForm Engineering GmbH, Switzerland:
European patents 1290515, 1623287, 1665103, 1741012 and US patents
7542889, 7623939. Other European, other US and JP patents pending.
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