Method planning based on simulation with Stampack offers process reliability before the actual tool is designed. It runs through the steps
We will now use an example from our daily design practice to show how these abstract steps are carried out in practice. We will look at the holder for a gas cartridge on the side airbag.
The difficulty with this component is that the perforated end face was required by the customer to be very flat. Therefore, the part has to be cut at this point from the side with a cam tool. However, the waste must not collide with the strip. The only way to ensure this is to move the part downwards before punching.
If you look at this idea, you as a toolmaker will get a stomach ache immediately. The connection is very thin and will be stretched strongly when moving downwards. In a first simulation the designer therefore gets an overview.
In the analysis one immediately sees two problem areas.
Failure in the connection:
The connection runs over the burr of the die and hence it is stretched too much at the end of the forming process, failure is the logical consequence. If you see the problem visually in Stampack, it is immediately clear that the burr must be flattened.
Failure at the bottom radius:
Cracks at the bottom radius can usually be avoided by improving the local material flow. For this purpose, the radius can be extended. However, this must be discussed with the end customer, because the change of the radius is a modification of the final product. After joint consideration of the simulation, the decision is made to expand this radius in the component.
After modifying the method, the designer carries out another simulation.
The simulation shows: All problems have been solved; the component is safe to produce. The component went into production without the construction of a prototype tool and produced a total of more than 400000 parts.