New product development is greatly aided by simulation software in a wide variety of sectors, including transportation, aircraft and healthcare. However, due to the prohibitive cost and learning curve associated with the software, such features are seldom offered at the supplier level.
While original equipment manufacturers (OEMs) may use simulations to test part design and functionality, metal stamping simulation software is used to ascertain whether or not the part can be manufactured as a metal stamping and how the tool for this purpose should be designed and constructed.
Engineers may test different material combinations and analyse tool design alternatives with the help of metal stamping simulation software. Metal stamping experts may save the time and money of their Original Equipment Manufacturer customers by utilizing simulation tools to design the component for manufacturability.
For Better Performance and Fewer Issues, Iterative Testing is Used
A simulation may go through as many as forty iterations to illustrate how a tool will create a component and if the metal supplied will function within those constraints before engineers settle on a final design for a new item that may push the boundaries of metal stamping. The program may need to run for many hours or even overnight if the simulation is large.
A common result of the simulation is the identification of design flaws or warnings that the metal may fracture or pull during manufacturing. New high-strength aluminium and magnesium are prone to springback, an issue that has to be addressed to prevent delays in manufacturing.
Complex geometries, such as linear bends and compound bends, may need simulation, while simpler requirements, such as straight 90-degree angles, may not.
It is possible to utilize simulation to assess already existing tools that have shown symptoms of borderline difficulties or intermittent downtime to figure out how to modify the tool to increase output. Again, the OEM may save money in the long run by using simulation software instead of having to develop and manufacture a whole new tool from scratch.
Prototyping in a Virtual Environment First May Save Time and Money
If you want to see whether a component could be stamped effectively with metal stamping tooling before the advent of metal stamping simulation software, you have to build a prototype of the tool first. A soft tool is a low-cost tool used in soft tooling to make a limited number of prototypes.
Presently, a virtual prototype might be created with the help of simulation programs. However, investing in both virtual and physical prototyping for a fresh product design may be the best way to prevent any quality concerns down the line.
The most important part of metal stamping is the design and construction of the instrument used to create the stamp. Metal stamping experts may avoid costly mistakes and assure a tool’s optimal performance by employing simulation software throughout the design phase. The program can suggest novel tool layouts, some of which may prove superior to the typical options. That means we can cut down or do away with the need for lengthy trial periods.
A metal stamper would have to create the tool using conventional parameters, test it in the press to see how it performs and make any necessary adjustments if the simulation weren’t used. However, it’s going to be costly and time-consuming to update the tool.
Material utilization and waste, as well as the tool’s long-term endurance, may all be affected by the design, with the latter two contributing to overall savings. If a tool doesn’t work as expected, it might slow down the production cycle.
Data-driven Design Enhancement for Increased Manufacturing Viability
Many factories cannot afford to put all of the metal stampings or other components of a new product through the DFM process. Because of this, precision metal stamping experts need to ensure the item can be manufactured as intended. The original equipment manufacturer (OEM) could push back if the DFM procedure suggests a redesign is necessary for a certain component since the part’s configuration affects the whole assembly.
Before the advent of metal stamping simulation software, manufacturers were forced to take their metal stamping provider at their word when they suggested that the component design be altered. The simulation has now shown everyone the evidence.
Engineers in the metal stamping industry may now collaborate through simulation to show how a component will or will not perform during the manufacturing process. The simulation program may also propose changes to the design of the component that can be swiftly and simply authorized.
Also Read: Why Stamping Components May Develop a Burr on Only One Side
