Page 35 - MetalForming February 2011

Die-Design Timesavers
Designers find that when adding specialized 3D die-design software to their 3D CAD software, they can dramatically reduce design time—by as much 30 to 50 percent depending on die size and complexity.
One immediate timesaver is the ability to flatten complex-shaped 3D stamped parts using finite-element- analysis (FEA) software. Some com- panies include FEA in their die-design software packages, while others offer it as an option. And, some FEA soft- ware goes beyond flattening and can automatically generate models for the intermediate part forms based on user input.
In less than 5 min., an insert can be added to a plate along with a shim or backup plate, with proper clearances for both, along with various corner treatments for the cavity in the plate receiving the insert.
When designing dies for parts that have only linear bends, often the 3D CAD package alone cannot unbend the parts, but the die-design unbend- ing software can. When the software unbends a part, it also can automat- ically calculate each bend’s k-factor. After parts are flattened or unbent, the software then can generate a strip layout, with punches, often in just a few minutes.
Die-design-specific software pack- ages also feature unique tools and utilities that significantly shorten the design process, such as the ability to quickly create cutting and forming punches. The software then will auto- matically cut all of the cavities through all plates in the die, applying
While these FEA tools prove very
handy, they will not replace dedicated FEA forming-simula- tion software packages, which prove particularly useful when working with complex stamped parts. These dedicat- ed FEA programs allow the designer to simulate forming and predict numerous outcomes including wrinkling, failure and springback—tasks that challenge even the most experi- enced tool and die maker—with incredible accuracy.
the correct clearances and tapers. In less than 5 min., an insert can be added to a plate along with a shim or backup plate, with proper clearances for both, along with various corner treatments for the cavity in the plate receiving the insert.
Some die-design software packages also include tools specifically for round parts. A designer can accurately process the intermediate steps for a round part and lay out a strip in
Tooling Technology
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