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VirtualConditioningof Progressive Dies

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SIMULATION IN DER UMFORMTECHNIK Virtual Conditioning of Progressive Dies Increasing Productivity and Quality Virtual Conditioning of Progressive Dies Increasing 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 CONNECTIVITY CONNECTIVITY ENERGY & ENERGY & INDUSTRIAL INDUSTRIAL CONSUMER CONSUMER AUTOMOTIVE AUTOMOTIVE 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 & Proprietary Do Not Reproduce or Distribute Session: Blechumformung
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Page 1: VirtualConditioningof Progressive Dies

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

Page 2: VirtualConditioningof Progressive Dies

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

Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute

Session : Blechumformung

Page 3: VirtualConditioningof Progressive Dies

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

Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute

Session : Blechumformung

Page 4: VirtualConditioningof Progressive Dies

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

Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute

page 8

Styles of Progression DiesStyles of Progression Dies

TE Stamping

Dies

Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute

Session : Blechumformung

Page 5: VirtualConditioningof Progressive Dies

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

Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute

Session : Blechumformung

Page 6: VirtualConditioningof Progressive Dies

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

Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute

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

Page 7: VirtualConditioningof Progressive Dies

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

Page 8: VirtualConditioningof Progressive Dies

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

Page 9: VirtualConditioningof Progressive Dies

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�!

Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute

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

Page 10: VirtualConditioningof Progressive Dies

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.

Information is TE Confidential & ProprietaryDo Not Reproduce or Distribute

•Divider Slide TitleThank you for your attention

Session : Blechumformung

Page 11: VirtualConditioningof Progressive Dies

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


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