Sheet metal forming is a manufacturing process in which flat sheet metal is drawn into a die cavity to form a product shape. Draw-in amount is the single most important metal stamping index that controls all forming characteristics (strains and stresses), formability failures (splits, wrinkles) and surface quality (distortions) on a panel.

Adaptation of a new die set for repetitively metal stamping sheet metal parts to a part design specification is simplified by using a math-based simulation of the metal stamping operation under specified engineering metal stamping conditions for the specified part. The metal stamping simulations are used to create an engineered draw-in map comparing selected locations on the peripheral edge of the stamped part with corresponding locations on the peripheral edge of its original sheet metal blank.

The resulting map of sheet metal draw-in dimensions reflect suitable displacements of the metal sheet between the binder ring and binder surface of the female die member at all such locations as the punch member of the die set executes its metal stamping operation. The engineered draw-in dimensions for a simulated part identify specific locations for adjustment of the binder ring/binder surface system in adapting the die set for production of parts.

A conventional three-component die set for metal stamping sheet metal parts consists of a punch, a binder ring and a female die. Such die sets are used to make many strong and light weight articles of manufacture. These articles include, for example,automotive body panels and other structure parts; aircraft and appliance sheet components; and beverage cans. Families of formable ferrous and aluminum sheet metal alloys have been developed for these manufacturing processes.

In a typical sheet metal forming operation, a flat blank of the metal is held at its periphery over the shaped cavity surface of a female die and the sheet is pulled into the cavity and against the shaped surface using a punch with a formingsurface complementary to that of the female die. The sheet is drawn and stretched between the tools and assumes a desired shape. In making stamped parts such as automotive body panels, often characterized by deep pockets and small radii bends, thepanel may be formed in stages using two or more sets of metal stamping dies each operated in a suitable hydraulic press.

In sheet metal stamping operations the blank is clamped at its periphery against the marginal surface of the female die cavity with a blank holder called the binder ring. The interaction between the binder ring, the interposed sheet and thebinder portion at the margin of the female die is critical to making a part that is formed free of wrinkles or tears. The binder ring has a bead that presses adjacent sheet metal into a complementary depression, a trough, in the binder portion of thefemale die to create proper restraining forces that prevent the sheet metal from being drawn to the die cavity too freely or too restrictively.

In a traditional die development and making process, a die is designed based on previous experience, and the die is validated through a series of physical tryouts. These tryouts are time consuming and costly and cannot guarantee the success ofthe die developments. For a typical automotive body panel, say a fender, the tryout alone could last twelve months and cost more than one million U.S. dollars. Today in math-based die development practice, the design of a die can be evaluated andreshaped through electronic tryout via advanced metal stamping simulation technology that consists of metal stamping CAE (computer aided engineering) programs, sheet metal forming simulation software (e.g., Pamstamp? and Dyna3D?) and high performancecomputers.

After the die sets for a vehicle body panel, for example, are designed or developed successfully in the digital world, the dies are constructed and tried out in a tooling shop. However, there are differences between the engineering of a die setand its everyday use in a manufacturing operation. And there are differences in results obtained between digital simulation of die operation and physical parts produced in a metal stamping plant. One aspect of the problem is that die makers are not sofamiliar with math-based die engineering principles that they can make good use of the math-based work in tuning actual dies for everyday metal stamping operations and ordinary sheet metal material. Therefore, physical tryout periods for each set ofmanufacturing dies can still take weeks or months because there has been no robust procedure by which manufacturing people can detect and correct differences between an actual die set and the math-based simulation from which it was built.

It is an object of this invention to provide a process for conforming actual sheet metal metal stamping experience using a specific die set with state-of-the-art math-based simulation of the die set and metal stamping operation. It is a more specific objectof this invention to provide a process for using the exact amount of sheet metal drawn in over the binder ring at selected locations around the periphery of the blank as a practical and effective basis to conform the operation of the physical die set tothe simulated performance of the virtual die set.

Die tryout workers can use the engineered draw-in map as a basis for correcting actual draw-in of the blank on the real die set. Where the sheet metal draw-in distance on the trial part is larger or smaller than the map dimensions suitablecompensation adjustments are made to the bead shapes to reduce or increase sheet metal flow. Invariably, as the actual draw-in values around the periphery of formed parts are brought into conformity with the simulated metal stamping draw-in values, good partsare produced.

The advantage of this invention is that die tryout workers can focus on draw-in of the sheet metal as the part is formed, one of the occurrences that they regularly observe in the making of each metal stamping. Now, with the use of the engineereddraw-in map, die tryout workers can more efficiently approach the die tryout process by conforming actual sheet metal draw-in dimensions with the math based simulation draw-in map and, where necessary, making adjustments to the beads at specificlocations identified from the draw-in map.

Article Source: http://www.articlesbase.com/online-business-articles/drawin-map-for-stamping-die-tryout-3298398.html

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In recent years, steady and rapid economic development, stimulating rapid growth in fixed assets investment, China Mould market demand. As the industry improve its competitiveness and national policy support, domestic Plastic mold industry output value and sales revenue for many years to maintain the growth rate of 20%. Die and Mould Technology, Shenzhen Institute of Deputy Secretary-General Luo Baihui Dongguan Daily News recently detailed the latest developments in the mold industry.

Auto, IT electronics industry mold market economy development impact

China imported the first negative mold growth, mold industry by the "one large and one small" pull, the development of really good the last two years. "A major" refers to the automotive industry, automobile industry refers to not only vehicle, as well as automotive components, such as the United States now become China's first second-largest auto parts exporter, which means that China's auto mold market has played an irreplaceable role. Its rapid development of mold plays an important role in driving, "a small" refers to the IT electronics industry. Total imports in 2006 Die 20.47 billion U.S. dollars 2.068 billion U.S. dollars in 2005 reduced the 21 million U.S. dollars, for the first time negative growth, stopped the momentum of the expansion of imports increased every year; exports totaled 1.041 billion U.S. dollars, more than an increase of 41.06 percent in 2005, for the first time over 10 billion dollars and imports to reduce the deficit down, is very gratifying.

Die need to further adjust the industrial structure

Although the mold industry and previous years has made significant progress, but there are still many problems. For example, the phenomenon of irrational industrial structure still exist. Structure, including product mix, technological structure, export structure, there are different degrees of problems. For example, in the import and export structure, due to the mold design and manufacturing standards and capabilities can not meet the market demand, therefore, die every year a large number of imports, especially high-end products. In 2006 the import and export stamping die, if by weight, priced at 14,913 U.S. dollars / t, and 5,869 U.S. dollars / t, much higher than the import export; while for plastic rubber mold, in 2006 imports and exports were 413,715 units and 1,217,772 units, exports is far greater than imports, while the unit is very different from the poor: the import price of 2532 U.S. dollars / set, the export price 602 U.S. dollars / set, a difference of four times, although the export volume was nearly 3 times the amount of imports, but still below the total amount of imports . That we are still importing large quantities of high quality molds, exports are dominated by middle and low. Therefore, in the long run, the rationalization of import and export trends should be expanded exports and reduce imports, making exports more than imports. Obviously, it also requires some time wanted to work.

Die enterprise development management constraints

Unlike mold process management product management, it is the face of the mold unit production industry, and how digital information management, is very learned. If the mold is not a scientific management, dynamic management approach, we can not guarantee orderly mold manufacturing, mold supplier in time. Meanwhile, each company's mold products are different, so they need individual management. Those who do well die business, they have a set of unique for their own management, but that too few companies. Luobai Hui pointed out that if the mold companies do not focus on management development will not go on, it has become a bottleneck restricting the development of enterprises mold problem.

City Government strongly support the building of mold

Since mold requires supporting the development of the product itself the characteristics of these years there were many places in China Mould City or Die Industrial Park, attracted everyone's attention. Luobai Hui said the park should die overall planning, dislocation development, make their own special characteristics. After a few years of development, indeed the city has developed some mold very good. For example, Hengli Town, the mold is very distinctive city: city of these enterprises into the mold, they are not forced to focus on a circle of walls, but the distribution in the zone, the only relatively concentrated, but enjoy the local Government policies to mold the park. Those hard to move together to pursue some form of mold park practice, not only is not conducive to enterprise development, on the contrary, conditions returned to the relocation of enterprises do not have to add many burdens. Luo Baihui that mold the city should fully reflect the cluster effect, the Government should lead the mold itself, supporting the development of upstream and downstream supply chain. For example, into the park's southern stamping die mold Union, had been at the location on the government's preferential policies to support Hengli, metal mold company in China and Thailand, driven by 12 companies shared the park, the establishment of automotive industrial park. Government support is the establishment of the healthy development of enterprises in the mold based on the work, indeed for the enterprise, rather than engage in face-saving projects, such companies would be welcome, would be more meaningful.

Association to play a bridging role between government and enterprises Die

As a bridge connecting the government and enterprises, mold Association has been kept hard at work. Tooling Technology Institute, Shenzhen, through the organization of exhibitions, stage shows to corporate structures; organization of technical exchange, so that more businesses learn the international advanced mold manufacturing technology; hold seminars to help companies find a way out, and ways of coping with the market, promote the progress of industry; through a "mold of key enterprises" in the election assessment, training a group of key backbone enterprises.

In addition, the Institute every year of the association named the National New Technology and New Products recommended to do the work, so that has been selected on the CAST enterprises to enter the field of vision, and enjoy some special policies, benefit the development of enterprises.

As association staff, often to the grassroots, to visit enterprises, to listen to the voice of enterprise, understand business needs, guide enterprises to put forward constructive ideas, for business and industry to do a lot of real things, make associations in the rapid prototype Shenzhen industry authority to improve. Today, the Association is anxious enterprise needs, like companies are thinking, digital information management work in the promotion.

Article Source: http://www.articlesbase.com/online-business-articles/rapid-prototype-china-mold-industry-news-2128273.html

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