Product development

Overview
End-to-end definition and validation of the production stamping process for a sheet-metal part. We develop the operation sequence (draw, redraws, trims, re-strikes, flanges), die faces (punch/die/binder/add-ons), binder and drawbeads, trim-line progression, and springback compensation, all backed by CAE to close a robust process window aligned to the target press.

Technical scope

• Operation sequence definition and forming strategy (number of stations, role of each).

• Initial die faces: punch, die, binder, add-ons, supports.

• Blank size & nesting with material utilization %.

• Drawbeads: type, placement, forces; DOE sensitivity.

• Trim optimization by operation, considering springback.

• Springback compensation to meet GD&T.

• Press validation: force/energy curves, stroke, shut height, peak/avg tonnage.

• Robustness study: thickness, friction/lube, material scatter.

• Basic transfer/robot feasibility (clearances, lifter angles, directions).

Benefits

• Fewer try-out loops and faster launch.

• Reduced rework risk on tooling and quality.

• Solid hand-off for detailed 3D tool design and production planning.

Deliverables

• Simulation Report (PDF):

  • Executive summary and conclusions.

  • Maps: FLD, thinning, wrinkling, contact/pressure.

  • Force/Energy curves per operation; recommended process window.

  • Drawbead design (locations, heights/penetrations, forces) and binder settings.

  • Recommended blank, draw-in, and material utilization %.

  • Trim progression by operation; springback results (pre/post compensation).

  • Risk register with countermeasures (radii, add-ons, supports, lube, etc.).

• CAD Files:

  • Die faces (draw/redraw/re-strike), binder, add-ons, beads.

  • Springback-compensated surfaces.

  • Trim curves by operation.

  • Blank DXF.

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

• Process plan sheets: sequence, station purpose, key parameters, target press, notes for detailed tool design.