Page 21 - MetalForming January 2010
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 any problems we would likely have encountered on the shop floor, without having to spend time and money to prove out our tooling concepts,” says Krish.
“The software saved us at least two weeks on the front end of the project, and also easily accommodated any engi- neering changes necessary along the way. Every problem that FormingSuite revealed in simulation we experienced with the prototype—thinning, splitting and wrinkling,” adds die designer Don Mikuluk.
FormingSuite Professional compris- es several software modules, including FastBlank for developing optimal blank geometry based on material stretch and deformation; FastForm Advanced for zeroing in on the forming conditions such as blankholder force, draw-bead placement and use of pressure pads; FastIncremental for detailed, LS-Dyna based formability analysis and simula- tion; and ProgNest for nesting blanks on progressive die strips to optimize mate- rial utilization based on coil width and pitch constraints.
“With each design iteration we were able to run simulations in less than one hour with the software,” continues Krish, “compared to a 4- to 5-day process of machining and remachin- ing die blocks. We gained confidence in our die designs in minutes rather than days.”
Under Budget and Ahead of Schedule
In the end, Boehm developed and built a 12-station progressive die in 12 weeks, well under the original time- frame, lower in price than the original tool set and which runs faster and uses 20 percent less material than did the previous process. And, the tool makes the brackets to original part-print dimensions.
“Our piece price is significantly lower than before,” says Krish, “and our die will run at 1000 parts/hr. with one oper- ator.” Originally, the hand-transfer tool set produced only 250 parts/hr., “on a good day,” Krish adds. MF
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