Formability Solutions in Production

Targeted diagnosis and correction of in-press formability issues—including excessive thinning, FLD/max-failure hot spots, wrinkling, edge cracking, earing, draw-in imbalance, and springback-related fit. We replicate your as-run conditions in CAE, run a focused DOE to rank levers, and deliver practical countermeasures you can apply on the floor.

When to use

• Launch/Ramp-up or SOP quality escapes

• Material/coil change, lubricant change, or press transfer changes

• Rate increase causing splits or wrinkles

• Vendor/tooling refurb switchovers

Technical scope

• Thinning & Max-Failure (FLD): hotspot mapping, blank/binder/drawbead tuning, radius/add-on proposals.

• Wrinkling control: local binder add-ons, bead relocation/penetration, restrike pad strategy, draw-in balance.

• Edge cracking: trim-line and edge-strain reduction (pre-trim, re-trim, restrike geometry), burr direction checks.

• Springback & fit: restrike surface updates and local compensation to meet GD&T.

• Friction/Lube: coefficient targets, application method, and sensitivity.

• Robustness: variation studies—thickness, n/r scatter, friction, bead wear.

• Press correlation: force/energy curves vs. simulation; recommended “press recipe.”

Deliverables

• Simulation Report (PDF):

  • Before/after maps: FLD, thinning, wrinkling likelihood, contact/pressure.

  • Root-cause summary and prioritized countermeasures with expected impact.

  • Focused DOE results and recommended process window.

  • Press recipe: binder force ranges, draw-bead penetrations/forces, draw-in targets, lube spec, and speed/stroke notes.

• CAD Files:

  • Updated die-face patches, restrike surfaces, bead curves/heights, trim-line revisions, and compensated surfaces.

  • Blank DXF (if revised).

  • Formats: STEP/IGES/DXF (native upon request).