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

ORIGINALARTICLEAPPLICATIONOFANINTEGRATEDCAD/CAE/CAMSYSTEMFORSTAMPINGDIESFORAUTOMOBILESBORTSUENLINNOCRACKORWRINKLEISPERMITTEDINTHEPRODUCTFORMCRACKORWRINKLESHALLBEMINIMIZEDINTHEADDENDUM,DRAWBEADANDBINDERFACETHESTRESSOFTHEPRODUCTFORMSHALLBESTRONGERTHANTHEYIELDSTRENGTHOFTHEBLANKINGMATERIALTOENSURETHATTHESTAMPINGPARTHASSUFFICIENTDENTRESISTINGSTRENGTHANDDURINGTHEDRAWINGPROCESS,THEBLANKPOINTSATWHICHTHEHIGHESTPOINTANDLOWESTPOINTOFTHEDIETOUCHSHALLBEWITHINTHEIRFEATUREFILLETSRADIITOAVOIDBLURRINGTHEFEATURE43DIEDESIGNSINCESTAMPINGDIESOFCARBODYPANELCANBEVERYLARGEINSIZE,THEYAREPROCESSEDBYCASTINGINORDERTOMINIMIZETHEIRWEIGHTANDCOSTINADDITION,CAMMECHANISMSAREUSEDINDIESFORDIFFERENTPRESSDIRECTIONSTOREDUCETHESTAMPINGPROCESSESANDCOSTTHEREFORE,THEDIEDESIGNCANBEVERYCOMPLEXDIESUSEDINTHISPAPERINCLUDEDRAWINGDIES,TRIMMINGDIES,ANDFLANGINGDIESA3DSOLIDMODEL,WHICHISIDENTICALTOREALPRODUCTS,ISUSEDINDIEDESIGNTOAVOIDANYINTERFERENCEANDTOFACILITATEDESIGNANDMODIFICATION,WHICHFUNDAMENTALLYREDUCESTHEDESIGNTIMEFIG6THEPROCESSOFFORMABILITYANALYSISFIG7THESIMULATEDMODELOFTRUNKLIDOUTERPANELINTJADVMANUFTECHNOL200835100010131005THEDESIGNPROCESSESOFEACHONEOFTHEAFOREMENTIONEDDIESAREBASEDONTHEPROCEDUREOUTLINESBYTHESTAMPINGDIEDESIGNKNOWLEDGEBASEDSYSTEM,ASSHOWNINFIG9INITIALDESIGNDESIGNERSNEEDTOGATHERAMINIMUMSETOFINFORMATIONABOUTTHEDIE,INCLUDINGDIEFACES,PUNCHOPENLINESPOLANDDIELAYOUTDIAGRAMINTHEDIELAYOUTDIAGRAM,WECANGETBLANKSIZES,DRAWINGSTROKES,PRESSMACHINESPECIFICATIONS,DIEHEIGHT,FEEDLEVEL,CUSHIONPINSTROKE,MACHINECENTER,DIECENTERANDSOONSKELETONDESIGNTHEMAINRESPONSIBILITYOFSKELETONDESIGNISTOIDENTIFYTHEMAINSTRUCTUREOFTHEDIE,INCLUDINGSIZESOFUPPERDIES,LOWERDIESANDBHS,THICKNESSOFDIEFACES,AVOIDSTRUCTURE,LAYOUTANDTHICKNESSOFRIBS,POSITIONSANDSIZESOFTHEGUIDEBOX,ANDSOONFUNCTIONALUNITDESIGNFUNCTIONALUNITDESIGNISTHEPROCESSOFDESIGNINGVARIOUSFUNCTIONALUNITSTHATAREUSEDTOSUPPORTDIEWORKINGTHESEFUNCTIONALUNITSINCLUDEUGROOVES,KEYGROOVES,HOOKS,ANDSOONSTANDARDPARTSDESIGNSTANDARDPARTS,SUCHASSLIDINGBOARDS,GASSPRINGS,ANDSPRINGS,AREALSOUSEDTOSUPPORTDIEWORKINGTHESESTANDARDPARTSAREAVAILABLEINTHEMARKETWITHDIFFERENTSIZESINTHEMEANTIME,THEDESIGNSOFSKELETON,FUNCTIONALUNITSANDSTANDARDPARTSAREALSOBASEDONTHECRITERIAANDSTANDARDSBYTHESTAMPINGDIEDESIGNKNOWLEDGEBASEDSYSTEM431DRAWINGDIEDESIGNDRAWINGDIESAREUSEDTOSHAPETHEPARTSINORDERTOOBTAINTHEDESIREDSHAPE,WENEEDVERYSTRONGFORMINGFORCE,WHICHMAKESITNECESSARYTOEVALUATEITSSTRUCTURALSTRESSESTHESTRUCTUREOFDRAWINGDIESINCLUDESDRAWINGPUNCH,DRAWINGCAVITY,STRENGTHENEDRIBS,GUIDINGPLANE,HOOKS,POSITIONINGSYSTEM,KEYGROOVE,UGROOVE,AND/ORBLANKPOSITIONINGUNITFORUPPERANDLOWERDIESETANDBLANKSFIG8FORMABILITYANALYSISRESULTSATHICKNESSDISTRIBUTIONBFLDDISTRIBUTIONCVONMISESSTRESSDISTRIBUTIONDTRACESOFTOUCHEDPOINTS1006INTJADVMANUFTECHNOL20083510001013HOLDERTHESELECTIONANDASSEMBLYOFTHESTANDARDPARTSFORDRAWINGDIESINCLUDESPRINGS,SCREWS,PINSANDGUIDEPLATESFIGURE10SHOWSA3DSOLIDDESIGNMODELOFTHEDRAWINGDIE432TRIMMINGDIEDESIGNTRIMMINGDIESAREUSEDTOCUTBLANKSSINCESCRAPSWILLNOTBEREMOVEDAUTOMATICALLY,WENEEDTOADDADDITIONALSCRAPCUTTERSWHERENECESSARYTHESTRUCTUREOFTRIMMINGDIESINCLUDESSTRENGTHENEDRIBS,UPPERANDLOWERCUTTERS,UPPERANDLOWERSCRAPCUTTERS,PAD,GUIDINGPLANE,HOOKS,POSITIONSYSTEMS,KEYGROOVEAND/ORUGROOVEFORTHEUPPERANDLOWERDIESETSTHESELECTIONANDASSEMBLYOFTHESTANDARDPARTSFORTRIMMINGDIESINCLUDESPRINGS,SCREWS,PINSANDGUIDEPLATESA3DSOLIDDESIGNMODELOFTHETRIMMINGDIEISSHOWNINFIG11433FLANGINGDIEDESIGNFLANGINGDIESAREUSEDTOFORMA90DEGREEFLANGEONTHEEDGEOFTHEPARTSSINCETHEREISANEAR90DEGREESHAPEONTHETRUCKLIDOUTERPANEL,INADDITIONTOTHEVERTICALBENDING,FIG103DSOLIDMODELOFDRAWINGDIEFIG9THEPROCESSOFDIEDESIGNFIG113DSOLIDMODELOFTRIMMINGDIEFIG123DSOLIDMODELOFFLANGINGDIEINTJADVMANUFTECHNOL200835100010131007WENEEDTOUSEACAMMECHANISMTOPERFORMAHORIZONTALBENDINGONTHEPARTTHESTRUCTUREOFFLANGINGDIESINCLUDESSTRENGTHENEDRIBS,UPPERANDLOWERWIPERS,APAD,GUIDINGPLANE,HOOKS,POSITIONINGSYSTEMS,KEYGROOVES,AND/ORUGROOVESFORTHEUPPERANDLOWERDIESETSTHESELECTIONANDASSEMBLYOFTHESTANDARDPARTSFORFLANGINGDIESINCLUDESPRINGS,SCREWS,PINSANDGUIDEPLATESASOLIDDESIGNMODELOFTHEFLANGINGDIEISDEVELOPEDASSHOWNINFIG12434INTERFERENCEANDSTRUCTURALANALYSESTHEDIESTRUCTURESHALLHAVESUFFICIENTSTRENGTH,ANDNOINTERFERENCEISALLOWEDAMONGTHEVARIOUSCOMPONENTSAFTERTHESOLIDMODELSHAVEBEENDEVELOPED,DESIGNERSUSETHECATIADIGITALMOCKUPMODULETOPERFORMMOTIONANDINTERFERENCEANALYSISONTHEMODELS,ASSHOWNINFIG13AFTERPERFORMINGTHISANALYSIS,ANYPOTENTIALINTERFERENCECANBEIDENTIFIEDANDAVOIDEDINADDITION,SINCETHESTAMPINGFORCEISVERYLARGE,ITISNECESSARYTOPERFORMASTRUCTURALANALYSISONTHEMODELSTHISANALYSISISPERFORMEDUSINGCATIAANALYSISANDSIMULATIONMODULUSINSTRUCTURALANALYSIS,DESIGNERSAPPLYFORMINGFORCESOBTAINEDFROMTHEFORMABILITYANALYSISANDTHEDIESBOUNDARYCONDITIONSTODETERMINETHESTRESSFIGURE14SHOWSTHESTRESSDISTRIBUTIONFORTHEBLANKHOLDEROFTHEDRAWINGDIETHEEVALUATIONCRITERIONOFTHESTRUCTUREANALYSISISTHATTHESTRESSOFTHEDIEMUSTBELESSTHANTHEYIELDSTRENGTHOFTHEDIEMATERIALDIVIDEDBYTHESAFETYFACTOR44DIEMANUFACTURETHEDIEMANUFACTUREINCLUDESTHEDISSOLVEDIEMANUFACTURE,THEDIEFACEMANUFACTUREANDTHEDIEDIMENSIONMANUFACTURETHEPROCESSOFDIEMANUFACTUREISSHOWNINFIG15441DISSOLVEDIEMANUFACTURESINCETHESTAMPINGDIEUSEDINTHISPAPERISPROCESSEDUSINGCASTING,DISSOLVEDIESMUSTBEUSEDSINCESHRINKANDDISTORTIONCANNOTBEAVOIDEDWHENCASTING,THESIZEOFTHEDISSOLVEDIESHALLBELARGERTHANTHATOFTHEACTUALDIEFOREXAMPLE,SINCETHEMATERIALOFTHEDIEBASEISFC25,THESIZEOFTHEDISSOLVEDIESHALLBE08PERCENTLARGERTHANTHATOFTHEDIEASARESULTOFPOSSIBLEDISTORTION,EXTRASPACE,WITHAMINIMUMOF10MM,SHALLBERESERVEDFOREVERYFIG13INTERFERENCEAREASOFTHETRIMMINGDIEFIG14STRESSDISTRIBUTIONFORTHEBLANKHOLDEROFTHEDRAWINGDIE1008INTJADVMANUFTECHNOL20083510001013PROCESSINGLOCATIONTHEPROCEDUREFORMAKINGDISSOLVEDIESISTOUSECADCEUSTODEVELOPANNCTOOLINGPATHPROGRAMFORTHEDISSOLVEDIESCNCMACHINESUSETHENCCODESTOMAKEDISSOLVEDIES,ASSHOWNINFIG16THEUSEOFCNCMACHINESSUCCESSFULLYREDUCESTHEMANUFACTURETIMEANDERRORRATE,ANDIMPROVESTHEQUALITYOFTHEDIES442DIEDIMENSIONMANUFACTUREDIEDIMENSIONMANUFACTUREISRESPONSIBLEFORMAKINGALLREFERENCEPLANESANDHOLESDIEDIMENSIONPROCESSINGALSOREQUIRESTHEDIESOLIDMODELTOBEFEDINTOTHECADCEUSSOFTWAREUSINGTHEIGESFORMATFILETHISPROCESSGENERATESTHETOOLINGPATHSANDSPECIFIESTHETYPEOFCUTTERBASEDONDIFFERENTPROCESSINGTYPESATTHESAMETIME,THELIFTINGHEIGHTSOFTHECUTTERMUSTALSOBESPECIFIEDTOAVOIDANYCONTACTWITHTHEDIEBODYTHEGUIDERPLANEISMACHINEDUSINGTHESIDEMILLINTHEVERTICALDIRECTIONWITHEVENPITCHTOENSUREITSACCURACYANDFLATNESSWHENTHETOOLINGPATHDESIGNISFINISHED,THECADCEUSSOFTWAREOUTPUTSTHENCCODES,WHICHWILLBEUSEDBYCNCMACHINES443DIEFACEMANUFACTURESINCETHEDIEFACEMANUFACTUREMUSTBEPERFORMEDONATHREEAXISCNCMACHINE,NOUNDERCUTTINGISPERMITTEDONANYSURFACEINORDERTOACHIEVETHEDESIREDPRECISION,THEPROCESSINGPATHEMPLOYSANEQUALSTEPAPPROACHATTHESAMETIME,THEABRASIONOFTHECUTTERMUSTBETAKENINTOCONSIDERATIONWHENPERFORMINGFINEPROCESSINGCUTTERSSHALLBEREPLACEDUSINGTHEATCAUTOMATICTOOLCHANGESYSTEMWHENNECESSARYTHESTAMPINGDIEFACESAREFEDINTOTHECADCEUSSOFTWAREUSINGIGESFORMATFILESTODEVELOPNCTOOLINGPATHSTOOLINGPATHDESIGNREQUIRESASETOFTOOLINGCONDITIONSTOBESET,WHICHINCLUDEPOSITIONSOFTOOLINGREFERENCEPOINTS,SIZESOFBALLCUTTER,FORMSOFTOOLINGPATHS,ROTATIONALSPEED,FEEDINGRATE,ANDCUTTINGPITCHINTHEMEANTIME,THEPROCEDURESOFTHEPROCESSMUSTALSOBEIDENTIFIED,WHICHINCLUDEROUGHING,FINISHING,ANDCORNERFINISHINGFIGURE17SHOWSTHETOOLINGPATHOFTHEDRAWINGPUNCHCNCMACHINESUSENCCODESGENERATEDBYCADCEUSTOHAVETHEDIESPROCESSEDINORDERTOENSURETHECORRECTNESSOFTHETOOLINGPATHS,ACUTTINGSIMULATIONMUSTBEPERFORMEDTOIDENTIFYANYPOTENTIALPROBLEMSSINCETHEDIESURFACEPROCESSINGISTIMECONSUMING,ATCSYSTEMSAREUSEDTOGETHERWITHTHECNCMACHINESTOENSUREAROUNDTHECLOCKMANUFACTURINGWITHOUTSUPERVISION,ASSHOWNINFIG18FIG15THEDIEMANUFACTUREPROCESSFIG16THEDISSOLVEDIESFORDRAWINGDIESFIG17TOOLINGPATHOFTHEDRAWINGPUNCHINTJADVMANUFTECHNOL20083510001013100945BUILDINGTHEDATABASEADATABASEISUSEDINOURSYSTEM,WHICHISORGANIZEDINATREESTRUCTURETHEROOTOFATREEISAPRODUCT,ANDBRANCHESOFTHETREECOMPRISETHEPROCEDURESOFPROCESSASSHOWNINFIG19,INFORMATIONISRETRIEVEDUSINGTHEPRODUCTNAMEOVERALOCALNETWORKSINCEFILESINIGESFORMATSAREACCEPTABLEBYALLCAD/CAE/CAMSOFTWARE,WEUSEIGESFORMATBASEDFILESTOEXCHANGEINFORMATIONWITHINOURSYSTEMTHELAYOUTDIAGRAMDESIGNUSESCATIASOFTWARETOGETTHEPRODUCTINFORMATIONINIGESFORMAT,ANDTOACHIEVELAYOUTDESIGNANDLAYOUTDIAGRAMSOFTHESTAMPINGDIEINTHEDIEFACEDESIGNPHASE,STRIMSOFTWAREISUSEDTOREADPRODUCTINFORMATIONINIGESFORMAT,COMPLETETHEDIEFACEDESIGN,ANDOUTPUTTHESURFACEINFORMATIONOFTHEDRAWINGDIEWHENPERFORMINGTHEFORMABILITYANALYSIS,DESIGNERSUSEDYNAFORMSOFTWARETOGETTHEDIEFACEINFORMATIONINIGESFORMAT,PERFORMFORMABILITYANALYSIS,ANDPREPAREANANALYSISREPORTINTHEDIEDESIGNSTAGE,CATIASOFTWAREISUSEDTOREADPRODUCTANDDIEFACEINFORMATIONINIGESFORMAT,COMPLETETHE3DSOLIDMODELDESIGN,THESTRUCTUREANALYSIS,ANDTHEMOTIONANDINTERFERENCEANALYSISATTHEENDOFTHISSTAGE,WEAREABLETOOBTAINA3DSOLIDMODELDESIGNANDREPORTSONTHERESULTSOFTHEVARIOUSANALYSESCADCEUSSOFTWAREISUSEDTOGETTHE3DSOLIDMODELANDDIEFACEINFORMATIONINIGESFORMATINTHEDIEMANUFACTUREPHASEDURINGTHISPHASE,DESIGNERSPERFORMTOOLPATHGENERATIONANDSIMULATION,ANDCOMPLETETHENCCODEANDTHECNCOPERATINGSEQUENCEALLAFOREMENTIONEDINFORMATIONISSAVEDINTHEDATABASEASSOONASITBECOMESAVAILABLEFIG19THECOMMUNICATIONSOFPRODUCTINFORMATIONFIG18CNCPROCESSINGOFTHEDRAWINGPUNCH1010INTJADVMANUFTECHNOL200835100010135RESULTSANDDISCUSSIONOFTHEINTEGRATEDSYSTEM51RESULTSASINTRODUCEDINTHEPREVIOUSSECTIONS,ONCETHEPARTSURFACEISAVAILABLE,STAMPINGDIEFACESARECONSTRUCTEDBYSTRIMANOPTIMALSTAMPINGDIEFACEISIDENTIFIEDAFTERAFORMABILITYANALYSISISPERFORMEDUSINGDYNAFORMINTHELAYOUTDIAGRAMDESIGN,ADIELAYOUTDIAGRAMISDEVELOPEDBYCATIABASEDONTHESTAMPINGDIEDESIGNKNOWLEDGEBASEDSYSTEMALLOFTHEREMAININGSUBTASKSAREBASEDONTHISDIELAYOUTDIAGRAMSOLIDMODELSOFSTAMPINGDIESARECONSTRUCTEDUSINGCATIABASEDONTHESTAMPINGDIEDESIGNKNOWLEDGEBASEDSYSTEMTHEMOTIONANIMATIONANDINTERFERENCEANALYSISAREPERFORMEDONTHISMODELTOFINDANYPOTENTIALINTERFERENCEINTHEMEANTIME,ASTRUCTURALANALYSISGIVESDESIGNERSAGOODUNDERSTANDINGOFTHESTRESSDISTRIBUTIONOFTHEDIENCPROGRAMSAREDEVELOPEDUSINGCADCEUSBASEDONTHESTAMPINGDIEFACESANDTHESOLIDMODELAFTERNCPROGRAMSHAVEBEENDEVELOPED,THECUTTINGSIMULATIONISPERFORMEDTOFINDANYPOTENTIALPROBLEMSSINCETHEENTIREDEVELOPMENTPROCESSUSESTHESAMEPARTDATAINTHEDATABASE,THESUBTASKSCANBEPERFORMEDSIMULTANEOUSLYINADDITION,IGESFORMATFILESAREUSEDTOEXCHANGEINFORMATIONAMONGCAD/CAE/CAMSOFTWAREANDTHEPRODUCTDATABASEFIGURE20SHOWSTHERESULTOFTHEDEVELOPMENT52COMPARISONBETWEENRESULTSFROMFORMABILITYANALYSISANDACTUALDRAWINGSAMPLESTHISPAPERUSESFORMABILITYANALYSISTOAVOIDSURFACEDEFLECTION,POORDENTINGRESISTANCE,ANDSURFACEBULGINGASSHOWNINTABLE1A,NOWRINKLEOCCURSWHENTHEBLANKISTIGHTLYHELDBETWEENTHEBLANKHOLDERANDUPPERDIETABLE1BSHOWSTHATRIPPLEPHENOMENAOCCURWHENTHETOPOFTHEPUNCHTOUCHESTHEBLANKSWHENTHERIPPLEPHENOMENONISSERIOUS,ITWILLLEAVESCARSONTHESURFACEOFTHEPARTSASSHOWNINTABLE1C,THEBULGEPHENOMENACOMEABOUTWHENTHEBOTTOMOFTHEUPPERDIESETTOUCHESTHEBLANKSWHENTHEBULGEPHENOMENONISSERIOUS,ITWILLLEAVESURFACEBULGINGONTHEOUTSIDECORNEROFTHELICENSEPLATEINDENTTABLE1DSHOWSTHATNODEFECTISFOUNDONPARTSURFACESEXCEPTFORTHEWRINKLESFOUNDONTHEBINDERFACESFIG20STAMPINGDIESANDSAMPLEPARTSA1DRAWINGDIEA2DRAWINGSAMPLEB1TRIMMINGDIEB2TRIMMINGSAMPLEC1FLANGINGDIEC2FLANGINGSAMPLEINTJADVMANUFTECHNOL2008351000101310116CONCLUSIONSTHISPAPERILLUSTRATESANINTEGRATEDCAD/CAE/CAMSYSTEMFORSTAMPINGDIEDEVELOPMENTOFTRUNKLIDOUTERPANELSUSINGACONCURRENTENGINEERINGAPPROACHTHESYSTEMCANGREATLYREDUCETHEDEVELOPMENTTIMEANDCOST,IMPROVETHEPRODUCTQUALITY,ANDPUSHPRODUCTSINTOTHEMARKETINARELATIVELYSHORTTIMETHESURFACESOFTHESTAMPINGPARTSAREVERYCOMPLEXANDSHARPEDGEDWHENDESIGNINGDIEFACES,ANOPTIMALDIEFACECANBEIDENTIFIEDAFTERFORMABILITYANALYSISISPERFORMEDTHISANALYSISCANGREATLYREDUCETHEDIETRYOUTTIMEANDFORMINGFAILURERATETHEENTIREDESIGNPROCESSUSESASOLIDMODEL,WHICHGREATLYREDUCESDESIGNTIMETHISMODELWILLGOTHROUGHMOTIONANDINTERFERENCEANALYSIS,ASWELLASSTRUCTURALANALYSISTOAVOIDANYDEFECTSACKNOWLEDGEMENTSTHISPROJECTISSPONSOREDBYTHENATIONALSCIENCECOUNCILOFTHEREPUBLICOFCHINACONTRACTNUMBERNSC922511S327001TABLE1COMPARISONOFTHEFORMINGPROCEDURESOFDRAWINGDIES1012INTJADVMANUFTECHNOL20083510001013REFERENCES1WICKC,BENEDICTJT,VEILLEUXRF1984TOOLANDMANUFACTURINGENGINEERSHANDBOOK,VOL2,FORMINGSOCIETYOFMANUFACTURINGENGINEERS,MICHIGAN2KEELERSP,BACKOFENWA1963PLASTICINSTABILITYANDFRACTUREINSHEETSSTRETCHEDOVERRIGIDPUNCHESTRANSASM5625493CHENFK,LIUJH1995ANALYSISOFDIEDESIGNSFORTHESTAMPINGOFANAUTOMOBILEREARFLOORPAN