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Application of an integrated CADCAECAM system for stamping dies for automobiles.pdf

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Application of an integrated CADCAECAM system for stamping dies for automobiles.pdf

ORIGINALARTICLEAPPLICATIONOFANINTEGRATEDCAD/CAE/CAMSYSTEMFORSTAMPINGDIESFORAUTOMOBILESBORTSUENLINCHUNCHIHKUORECEIVED2MARCH2006/ACCEPTED4SEPTEMBER2006/PUBLISHEDONLINE17NOVEMBER2006SPRINGERVERLAGLONDONLIMITED2006ABSTRACTTHEGLOBALIZATIONANDCOMPETITIONINTHEAUTOMOBILEINDUSTRYMAKESITNECESSARYTOREDUCETHETIMESPENTONPRODUCTDEVELOPMENTTHEREFORE,COMPUTERAIDEDPRODUCTDEVELOPMENTHASBECOMEONEOFTHEMOSTIMPORTANTTECHNIQUESINTHEAUTOMOBILEINDUSTRYACCORDINGTOTHECONCURRENTENGINEERINGCONCEPT,ANINTEGRATEDCAD/CAE/CAMSYSTEMFORAUTOMOBILESTAMPINGDIEDEVELOPMENTISESTABLISHEDTHESYSTEMISBASEDON3DSURFACECONSTRUCTIONCADSOFTWARESTRIM,CAD/CAESOFTWARECATIA,STAMPINGFORMABILITYANALYSISSOFTWAREDYNAFORM,CAMSOFTWARECADCEUS,ASTAMPINGDESIGNKNOWLEDGEBASEDSYSTEM,ANDAPRODUCTDATABASETHISPAPERUSESTHEDEVELOPMENTOFTRUNKLIDOUTERPANELSASANEXAMPLETOSHOWCASETHEPOWEROFTHESYSTEM,INWHICHTHEDIFFERENTDEVELOPMENTSTAGESCANBEPERFORMEDSIMULTANEOUSLYTHESYSTEMCANGREATLYREDUCETHEDEVELOPMENTTIMEANDCOST,IMPROVETHEPRODUCTQUALITY,ANDPUSHPRODUCTSINTOTHEMARKETINARELATIVELYSHORTTIMEKEYWORDSINTEGRATIONCAD/CAE/CAMCONCURRENTENGINEERINGSTAMPINGDIEAUTOMOBILEDRAWINGDIE1INTRODUCTIONSINCESTAMPINGPARTSHAVECONSIDERABLEPOTENTIALBECAUSEOFTHEIRCOMPETITIVEPRODUCTIVITYANDPERFORMANCE,THEYHAVEBEENWIDELYUSEDINTHEAUTOMOTIVEINDUSTRYHOWEVER,THEMANUFACTURINGINDUSTRYHASTHREEMAJORGOALSTOIMPROVEPRODUCTQUALITY,TOREDUCEDEVELOPMENTCOST,ANDTOREDUCETHETIMESPENTONDEVELOPMENTINORDERTOACHIEVETHESEGOALS,WENEEDTOBRINGINNEWTECHNOLOGIESFROMTHEMANUFACTURINGVIEWPOINT,THEMAJORREQUIREMENTFORMOSTAPPLICATIONSOFSHEETMETALISGOODFORMABILITY1GIVENTHATPARTSURFACESHAVEBECOMEMOREANDMORECOMPLEXANDSHARPEDGED,WENEEDTOTAKEADVANTAGEOFFORMABILITYANALYSISTOUNDERSTANDTHEIRSTAMPINGPROPERTIESIN1963,KEELERANDBACKOFEN2INTRODUCEDTHECONCEPTOFFORMINGLIMITDIAGRAMSFLDSTHEYANALYZEDTHESHAPEANDSIZEFORANETCHEDCIRCLEGRIDOFSHEETMETALAFTERITHADBEENSTAMPEDTHISTECHNIQUEHASBEENWIDELYUSEDINSHEETMETALFORMABILITYANALYSISSINCETHENRECENTLY,SOFTWARETHATUSESAFINITEELEMENTMETHODHASBEENUSEDTOANALYZEANDSIMULATESHEETMETALFORMABILITYCHENANDLIU3COMBINEDCIRCLEGRIDANALYSISWITHFORMABILITYANALYSISTOIDENTIFYANOPTIMALDIEFACE,SOTHATTHESPLITDEFECTATTHEDRAWNCUPWALLINTHEREARFLOORPANELCOULDBEAVOIDEDMAKINOUCHI4USEDFORMABILITYANALYSISSOFTWARETOANALYZEFOURSTAMPINGPARTSFENDERS,TRUNKLIDOUTERPANELS,SIDEFRAMEOUTERPANELS,ANDTIREDISKWHEELSANDTOPREDICTTHEIRBLANKGEOMETRY,SPRINGBACK,SHEETTHICKNESS,RESIDUALSTRESS,ANDCOMMONDEFECTSAFTERSTAMPINGBIGOTETAL5DEVELOPEDAMETHODOLOGYTOVALIDATETHEMODELINGOFANALUMINUMFORMINGPROCESSBASEDONDIMENSIONALCHARACTERIZATIONANDFINITEELEMENTCOMPARISONTAKINGADVANTAGEOFARTIFICIALNEURALNETWORK,KNOWLEDGEBASEDSYSTEMSANDFINITEELEMENTANALYSIS,PILANIETAL6PROPOSEDAMETHODFORAUTOMATICALLYINTJADVMANUFTECHNOL2008351000–1013DOI101007/S001700060785YBTLINCCKUODEPARTMENTOFMECHANICALANDAUTOMATIONENGINEERING,NATIONALKAOHSIUNGFIRSTUNIVERSITYOFSCIENCEANDTECHNOLOGY,2JUOYUERD,NANTZDISTRICT,KAOHSIUNG,TAIWAN,REPUBLICOFCHINABTLINDEPARTMENTOFMECHANICALANDAUTOMATIONENGINEERING,NATIONALKAOHSIUNGFIRSTUNIVERSITYOFSCIENCEANDTECHNOLOGY,1UNIVERSITYROAD,YENCHAO,KAOHSIUNG,824TAIWAN,REPUBLICOFCHINAEMAILBT_LINCCMSNKFUSTEDUTWGENERATINGANOPTIMALDIEFACEDESIGNBASEDONDIEFACEFORMABILITYPARAMETERSSINCEDIESTRUCTURESAREBECOMINGMOREANDMORECOMPLEXANDLARGESIZED,WEMUSTUSEASOLIDMODELINDIEDESIGNTOAVOIDANYPOTENTIALINTERFERENCEAMONGTHEVARIOUSCOMPONENTSMOREOVER,THESOLIDMODELCANBEUSEDFORBUILDINGDISSOLVEMODELSANDESTIMATINGTHEFRAGILESECTIONOFDIESTRUCTURESTHEREFORE,ITISNECESSARYTOUSEA3DCAD/CAE/CAMSYSTEMTOBUILDSOLIDMODELS,TODEVELOPCNCTOOLINGPATHPROGRAMS,ANDTOANALYZETHESTRESSOFDIESTRUCTURESWHENDEVELOPINGSTAMPINGDIESNAHMANDISHIKAWA7UTILIZEDTHESETBASEDDESIGNAPPROACHWITHTHEPARAMETRICMODELINGTECHNIQUETOHANDLETHEUNCERTAINTIESTHATAREINTRINSICATEARLYSTAGESOFTHEDESIGNPARKETAL8COMBINEDACAD/CAMSYSTEMWITHAKNOWLEDGEBASEDSYSTEMTODEVELOPDEEPDRAWINGDIESOFTHEMOTORHOUSINGCHENGETAL9USEDVISUALCPROGRAMMINGTOCREATECADSOFTWAREFORTHECONCEPTUALDESIGNOFTHESCROLLCOMPRESSOR,ANDFABRICATEAREALORBITINGSCROLLPARTONACNCMACHININGCENTERTHEGLOBALIZATIONANDCOMPETITIONINTHEAUTOMOTIVEINDUSTRYMAKESITNECESSARYTOREDUCETHETIMESPENTONPRODUCTDEVELOPMENTNETWORKSAREWIDELYUSEDNOWADAYSASARESULT,KAOANDLIN10DESIGNEDASYSTEMTHATUSESALOCALAREANETWORKANDTHEINTERNETTOALLOWTWOGEOGRAPHICALLYDISPERSEDCAD/CAMUSERSTOSIMULTANEOUSLYWORKONTHEDEVELOPMENTOFPRODUCTSKONGETAL11DEVELOPEDANINTERNETBASEDCOLLABORATIONSYSTEMFORAPRESSDIEDESIGNPROCESSFORAUTOMOBILEMANUFACTURERSTOSHEARDESIGNMODELSANDANALYSISRESULTSMOREOVER,ANINTEGRATEDCAD/CAE/CAMSYSTEMCANTREMENDOUSLYIMPROVEPRODUCTIVITYXUANDWANG12USEDTHEMULTIMODELTECHNOLOGYANDANINTEGRATEDCAD/CAE/CAMSYSTEMTODEVELOPCYLINDERHEADYUEETAL13TOOKADVANTAGEOFTHECONCURRENTENGINEERINGCONCEPTANDDEVELOPEDANINTEGRATEDCAD/CAE/CAMSYSTEMTODEVELOPDIECASTINGDIESFORWATERPUMPS,WHICHSUCCESSFULLYREDUCETHEDEVELOPMENTTIMEANDCOST,ANDIMPROVEPRODUCTQUALITYFERREIRA14DEVELOPEDANINTEGRATEDCAD/RP/FEASYSTEMTOIMPROVETHEMANUFACTURINGPROCESSFORZNCASTINGTHISPAPERILLUSTRATESANINTEGRATEDCAD/CAE/CAMSYSTEMFORDESIGNINGSTAMPINGDIESOFTRUNKLIDOUTERPANELSFORAUTOMOBILESUSINGCONCURRENTENGINEERINGCE2PROCEDURESFORDEVELOPINGSTAMPINGDIESFORAUTOMOBILESONCERECEIVINGTHESURFACEMODELOFASTAMPINGPARTFROMANAUTOMOBILEMANUFACTURER,THEDIEMANUFACTURERINITIALIZESTHEDEVELOPMENTPROCESS,WHICHISSHOWNINFIG1DIEFACEDESIGNISAPROCESSTHATUSESCADSOFTWARETOCREATE3DDIEFACES,WHICHINCLUDESTAMPINGPARTSURFACES,ADDENDUMS,DRAWBEADSANDBINDERFACES,ANDANALYZESTHEIRSTAMPINGPROPERTIESUSINGFORMABILITYANALYZINGSOFTWARETAKINGPOSSIBLECOMMONDEFECTSINTOCONSIDERATION,DESIGNERSKEEPMODIFYINGTHE3DSURFACESUNTILTHEYOBTAINANOPTIMALDRAWINGDIEFACE,WHICHWILLBEUSEDINDESIGNINGDIESANDDESIGNINGNCPROGRAMSFORPROCESSINGDIEFACESLAYOUTDIAGRAMDESIGNISTHEPROCESSOFDEVELOPINGTHEDIELAYOUTDIAGRAMBASEDONITSSURFACEMODEL,WHICHINCLUDESTHEFOLLOWINGSUBTASKSIDENTIFYINGTHECENTRALREFERENCEPOINT,IDENTIFYINGTHEPRESSDIRECTION,IDENTIFYINGTHERESPONSIBILITIESOFEACHPROCESS,DESIGNINGDRAWINGDIEFACES,SUGGESTINGDIEHEIGHTANDINDICATINGPRESSLINESSINCEAUTOMOTIVESTAMPINGDIESCANBEVERYLARGEINSIZE,THEYAREPROCESSEDBYCASTINGINORDERTOMINIMIZETHEIRWEIGHTANDCOST3DCAD/CAESOFTWAREMUSTBEUSEDTODESIGNTHESOLIDMODELTOAVOIDANYPOTENTIALINTERFERENCEAMONGVARIOUSCOMPONENTS,WHICHINCLUDESCAVITY,PUNCH,STRENGTHENEDRIBS,FUNCTIONALUNITSAND/ORSTANDARDPARTSFORUPPERANDLOWERDIESETS,ANDBLANKHOLDERBHAFTERTHEDIEDESIGNPROCESSISFINISHED,DESIGNERSWILLPERFORMMOTIONANDINTERFERENCEANALYSISONTHE3DSOLIDMODELSANDMODIFYTHEMIFANYPROBLEMISIDENTIFIEDMOREOVER,THESTAMPINGFORCEISVERYLARGE,MODIFICATIONANDENHANCEMENTSHOULDBEMADETOTHEDIESTRUCTURALMODELSWHERENECESSARYTHROUGHSTRUCTURALANALYSISDIEMANUFACTUREINCLUDESDISSOLVEDIESMANUFACTURE,DIEDIMENSIONMANUFACTUREANDDIEFACEMANUFACTUREDISSOLVEDIESARENEEDEDBECAUSEDIEBODIESAREPROCESSEDBYCASTINGAFTERIDENTIFYINGTHEINFORMATIONNEEDEDTOCONSTRUCT3DSOLIDMODELS,DESIGNERSSHOULDDEVELOPNCTOOLINGPATHPROGRAMSTOMAKEDISSOLVEDIESUSINGCNCMACHINESTHEN,THEDIEBODIESARECASTTHROUGHDISSOLVEDIESDIEDIMENSIONMANUFACTUREISRESPONSIBLEFORMAKINGALLREFERENCEPLANESANDHOLES,SUCHASDIEBASEPLANES,GUIDINGPLANES,STOPPERPLANES,ASSEMBLINGPLANES,POSITIONINGHOLESFIG1ADEVELOPMENTFLOWCHARTFORSTAMPINGDIESINTJADVMANUFTECHNOL2008351000–10131001ANDBOLTHOLESDIEFACEMANUFACTUREGENERATESALLSURFACESTHATWILLBECOMPLETEDINALLSUBSEQUENTSUBTASKSDESIGNERSUSE3DCAMSOFTWARETODESIGNTOOLINGPATHS,INCLUDINGROUGHING,FINISHING,ANDCORNERFINISHINGPATHSMOREOVER,CUTTINGSIMULATIONNEEDSTOBECONDUCTEDTOENSURETHEFEASIBILITYOFTHEPROCESSAFTERTHETOOLINGPATHSHAVEBEENIDENTIFIED,THEYWILLBEPOSTEDINTONCCODETOALLOWFURTHERPROCESSINGBYCNCMACHINESWHENTHEDIESHAVEBEENMANUFACTUREDANDASSEMBLED,CMMCOORDINATEMEASURINGMACHINESWILLMEASURETHEDIMENSIONSOFTHEDIESIFNOFAULTSAREFOUND,DIETRYOUTSWILLBEPRODUCEDIFTHETRYOUTSMEETALLREQUIREMENTSANDSPECIFICATIONS,MASSPRODUCTIONENSUES3THEINTEGRATEDCAD/CAE/CAMSYSTEMSFIGURE2SHOWSTHESCHEMEOFTHEINTEGRATEDCAD/CAE/CAMSYSTEMFORSTAMPINGDIESTHISSYSTEMINCLUDESASETOFCADDIEFACEDESIGNSOFTWARE,ASETOFSTAMPINGFORMABILITYANALYZINGSOFTWARE,ASETOFCAD/CAESOFTWARE,ASETOFCAMSOFTWARE,ASTAMPINGDIEDESIGNKNOWLEDGEBASEDSYSTEM,ANDAPRODUCTDATABASEDIEFACEDESIGNISTHEPROCESSOFDESIGNINGVARIOUSSUPPORTINGSURFACESAROUNDTHESTAMPINGPARTSURFACESTHESESUPPORTINGSURFACESARENOTPARTOFTHESTAMPINGPARTSURFACESTHEREFORE,THEDIEMANUFACTURERISRESPONSIBLEFORTHEDIEFACEDESIGNINORDERTOENSURECONSISTENCYBETWEENTHESTAMPINGPART’SSURFACESANDITSSUPPORTINGSURFACES,SPECIALIZEDSURFACEDESIGNCADSOFTWAREMUSTBEUSEDCOMMONLYUSEDCOMMERCIALSOFTWAREINCLUDESICEMSURFBYICEM,STRIMBYSGI,ANDCATIABYDASSAULTTHESURFACESOFAUTOMOTIVEPARTSAREVERYCOMPLEXANDSHARPEDGEDTHEIRFORMABILITYCANNOTBEPREDICTEDUSINGPREVIOUSEXPERIENCEINORDERTOENSUREPRODUCTQUALITY,DESIGNERSNEEDTOPERFORMFORMABILITYANALYSISONDIEFACESBEFOREDESIGNINGSTAMPINGDIECURRENTLY,THISKINDOFSOFTWAREINCLUDESDYNAFORMBYETA,PAMSTAMPBYEDS,ANDAUTOFORMBYAFEAUTOMOTIVESTAMPINGDIESTRUCTURESINCLUDESTRUCTURALSUBCOMPONENTS,SUCHASPUNCH,CAVITY,STRENGTHENEDRIBS,FUNCTIONALUNITS,ANDCAMMECHANISMS,WHICHAREUSEDTOCHANGETHESTAMPINGDIRECTIONANDREDUCEDIESIZESTHEDIEFACESOFPUNCHANDCAVITYAREMADEUPOFTHOUSANDSOFSURFACESTHESECOMPONENTSALSOMAKETHEDESIGNJOBEXTREMELYCOMPLEXWHENDESIGNINGLAYOUTDIAGRAMSDESIGNERSUSEPLANEDIAGRAMSTOILLUSTRATELAYOUTSOFDIESWHENDESIGNINGDIES,DESIGNERSUSESOLIDMODELSTOCONSTRUCTDIESTHATAREIDENTICALTOREALDIESMOREOVER,DESIGNERSUSEMOTIONANDINTERFERENCEANALYSISTOAVOIDANYPOTENTIALINTERFERENCEAMONGVARIOUSCOMPONENTSINTHEMEANTIME,STRUCTURALANALYSISISPERFORMEDTOUNDERSTANDTHEIRSTRESSESANDSTRAINSRELATEDSOFTWARETHATISAVAILABLEINTHEMARKETINCLUDESCATIABYDASSAULT,PRO/ENGINEERBYPTC,ANDUNIGRAPHICSNXBYEDSDUETOTHECOMPLEXSTRUCTUREOFAUTOMOTIVESTAMPINGDIES,CNCMACHINESSHOULDBEUSEDTOMANUFACTURESTAMPINGDIESTHEREFORE,CAMSOFTWARESHOULDBEABLETOASSISTDESIGNERSTOGENERATETOOLINGPATHSANDPROVIDECUTTINGSIMULATIONTHEREAREMANYCAMSOFTWAREPACKAGESFIG2THEGENERALSCHEMEOFTHEINTEGRATEDCAD/CAE/CAMSYSTEMOFSTAMPINGPRODUCT1002INTJADVMANUFTECHNOL2008351000–1013THATCANSUPPORTTHEAFOREMENTIONEDFEATURES,INCLUDINGPOWERMILLBYDELCAMANDCADCEUSBYUNISYSTHECONSTRUCTIONOFASTAMPINGDESIGNKNOWLEDGEBASEDSYSTEMINCLUDESLAYOUTDESIGNANDDIEDESIGNTHELAYOUTDESIGNINCLUDESTHEEMPIRICALFORMULAFORSURFACEFORMINGPARAMETERS,SUCHASTHETHICKNESSOFSHEETS,DIECLEARANCES,FILLETSRADIIANDSPRI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