Simulation in der umFormteCHniK
Virtual Conditioning of Progressive DiesIncreasing Productivity and Quality
Virtual Conditioning of Progressive DiesIncreasing Productivity and Quality
Erich Köhnert
Manager DIE Design Wört
TE, Automotive
page 2
(FY2011 Results)
has a 50-plus year
history of leadership
TE Connectivity …TE Connectivity …
BROADBAND BROADBAND CONNECTIVITYCONNECTIVITY
ENERGY &ENERGY &
INDUSTRIALINDUSTRIAL
CONSUMERCONSUMER
AUTOMOTIVEAUTOMOTIVE
is a $14,3 billion company
is a global company
with nearly 100,000
employees
Customers
has over 500,000
products
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
Session : Blechumformung
Simulation in der umFormteCHniK
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
page 3
AutomotiveAutomotive
Cable Assembly
Systems
Inductive
Systems
Infotainment
Alternative
Power Systems
Sensor
Technology
Relays
Terminals
and
Connectors
Wire and Tubing
page 4
TE Location Wört - AutomotiveTE Location Wört - Automotive
Stamping Wört
- High speed stamping
- Progressive Dies for high volume production
~ 15 billion producedparts in FY 2011
Stamping is a key technology within TE Connectivity
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Session : Blechumformung
Simulation in der umFormteCHniK
page 5
Presentation TopicsPresentation Topics
• Virtual conditioning
• Situation before Finite Element Analysis (FEA)
implementation
• Quality improvements by FEA
• Increasing productivity in tool shop by FEA
• Outlook
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
page 6
Virtual ConditioningVirtual Conditioning
What is Virtual Conditioning?
�To eliminate trial & error during fine tuning
�To simulate forming during die design phase
�To fix the proper blank profile at the first time
�To determine the right spring load
�To do feasibility studies w/o physical attempts
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Session : Blechumformung
Simulation in der umFormteCHniK
page 7
Forming features at terminals & connectorsForming features at terminals & connectors
Wire Area
Transition
Transition
Contact Body
Insulation Area
Carrier Strip
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page 8
Styles of Progression DiesStyles of Progression Dies
TE Stamping
Dies
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
Session : Blechumformung
Simulation in der umFormteCHniK
page 9
Presentation TopicsPresentation Topics
• Virtual conditioning
• Situation before Finite Element Analysis (FEA)
implementation
• Quality improvements by FEA
• Increasing productivity in tool shop by FEA
• Outlook
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
page 10
Before FEABefore FEA
testing
weldinggrinding
filing polishing
not OK
OK
INPUT
OUTPUT
In the past, many loops of optimization were required to get the right result.
These approaches …- took much time- needed much rework- caused high costs- spent resources of toolmaker‘slabor
- permitted no reproducibleprocesses
- bred a lot of discussions
~ 6
–20 w
eeks
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Session : Blechumformung
Simulation in der umFormteCHniK
page 11
Toolmaker Toolmaker
Conditioning is mainly performed by toolmakers and
by hand.
Profiling by using a file
Continuous checking of form
Adapting the tool shape
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page 12
Situation in the PastSituation in the Past
It was toolmaker‘s work! (3D shape)
U-ing stationU-ing insert
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
Session : Blechumformung
Simulation in der umFormteCHniK
page 13
Presentation TopicsPresentation Topics
• Virtual conditioning
• Situation before Finite Element Analysis (FEA)
implementation
• Quality improvements by FEA
• Increasing productivity in tool shop by FEA
• Outlook
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
page 14
Results of Quality Improvement by FEAResults of Quality Improvement by FEA
After modification lower damage values
�no cracks.
Smooth surface
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
Session : Blechumformung
Simulation in der umFormteCHniK
page 15
Presentation TopicsPresentation Topics
• Virtual conditioning
• Situation before FEA implementation
• Quality improvements by FEA
• Increasing productivity in tool shop by FEA
• Outlook
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
page 16
Bending test
• Input from tensile test: Rm, Rp02, Epsilon, Youngsmodulus.
• Modifying material properties
• Goal: Angle(FEA)= Angle(Bendingdevice)
• Modified material properties for FEA in 3D
Determine Material CharacteristicsDetermine Material Characteristics
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
Session : Blechumformung
Simulation in der umFormteCHniK
page 17
Breakthrough Innovation by FEABreakthrough Innovation by FEA
First FE-trial to getthe shape of thebody area with givenlayout
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Not 90�!
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page 18
Breakthrough Innovation by FEABreakthrough Innovation by FEA
Modified layout by rotating walls in CAD and start another analysis with FEA
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90�!
Rotate
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
Session : Blechumformung
Simulation in der umFormteCHniK
page 19
DIE Design
Future
Today
Past Part
fabrication
Assembly Conditioning
IdeaProcessing stages of a stamping die /
Time to marketFinal Product
Increasing Productivity in Tool Shop by FE AnalysisIncreasing Productivity in Tool Shop by FE Analysis
DIE Design Part
fabrication
Assembly Conditioning
FE-Analysis
DIE Design &
FE-Analysis
Part
fabrication
Assembly
Simulation
Potential
Zero
cond.
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•Divider Slide TitleThank you for your attention
Session : Blechumformung
Simulation in der umFormteCHniK
page 21
InfoInfo
• TE Connectivity, TE connectivity (Logo) are trademarks
• © 2012 Tyco Electronics
• www.te.com
Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute
Session : Blechumformung