Reduced Lead Time through Advanced Die Structure Analysis
Purpose and goal
The aim of the project was to reduce the lead time for press tools through virtual try-out and increased supplier collaboration. Goals achieved: Suggeted new working methods for supplier networks that minimize lead time and risks when developing tools, with special focus on design and tryout times. Effective methods linking forming and structure mechanics simulations. Reliable methods for scanning, measuring and calculating deformations and other process parameters to understand the difference between different production equipment.
Expected results and effects
The project has developed models for analysis, optimization and compensation of forming surfaces in tools, that are so time-efficient that you can radically reduce the run-in time for each press tool. In addition, the results have been collected in the form of guidelines. The supplier network has evaluated new communication methods within the value chain, but has not been able to test and analyze these in commercial projects.
Planned approach and implementation
The work has been carried out by tool manufacturers collaborating with customer and supplier networks, and was coordinated by RISE IVF. Process mapping, log books and in-depth interviews identified proposals for new communication methods. Methods to link forming and structure analysis simulations were developed in Johan Pilthammar´s PhD in collaboration with MSc students. Experiments were developed by RISE IVF, Cascade, Volvo Cars, Speedtool, BTH. Three different presses were analysed with the new measurement methods, and the results were used to update the numerical models.