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Enhanced computer-based design and Promotion of sheet stamping Dies

Objective


The objective of this project is to develop and validate a computer system (the PRODIES system) that can be effectively used by SME's for design, manufacturing and quality assurance of sheet stamping dies.

The sought PRODIES system was on an existing code, named STAMPACK, developed by CIMNE for sheet stamping analysis. The current version of STAMPACK as developed in the project includes unique capabilities, which make the code, as it is, competitive with existing sheet stamping software available in the market. Among these capabilities we can list the possibility for parallel computing in networks of PC operating in Windows, the capacity for performing elastic spring-back analyses in a fast manner, the possibility of including draw-beads in the analysis, the prediction of manufacturing defects and the integration of advanced pre and post processing facilities.
The specific project objectives included the following:

* Development and integration of material properties, defect prediction module and tool databases into the existing version of STAMPACK.
* Enhancement of user's interfaces of STAMPACK following the specification of SME die manufacturers.
* Development of the PRODIES computer system for die design in SME's running in parallel in PC networks under Windows.
* Implementation of PRODIES system in the premises of the SME's participating in the project. Training of technical staff into the use of the code.
* Experimental validation and feed back enhancement of the PRODIES system.
* Specification of a computer based methodology for enhanced design and production of sheet stamping dies.

The final aims of the project were to make available to SME's a new computer system for enhanced design and manufacturing of stamping dies. The system has been based on existing software developed by the RTD partners. No software module was therefore been developed from scratch and this has reduced the project time scales as well as increased the chances of a successful outcome.

The following technical developments have formed the core of the planned improvements of the current version of the STAMPACK code towards the new PRODIES system.

- Improvements in the user interface of STAMPACK by using the advanced pre/post-processing system GiD recently developed at CIMNE.
- Enhancement in defect prediction module and material database
- Improving the graphic visualization module via the use of the GiD system above mentioned
- Enhancements in the code documentation
- Setting up of a continuing distance training systems base on internet link.

The end user oriented graphic interface of the PRODIES system has made use of the general purpose pre- and post-processor GID developed by CIMNE during last five years. This interfacing task and further enhancements/ alterations were based on the end-users feedback.

The detection of possible defects during the sheet forming stage was performed using simple but quite reliable parameters. Many defects resulting from spring back, cutting operations or multistage forming analysis are available within the software: plastic strains, residual stresses, unpredicted deformations all form part of the information output from this analysis. Further micro-porosity defects can be predicted using simple measures following the philosophy of recent defect prediction models developed by CIMNE.

The evaluation of the efficiency of the new PRODIES system has been made by means of comparison of numerical results obtained in the analysis of industrial sheet stamping problems already available to the SME end user companies. The solution of a number industrial sheet stamping problems was attempted. These tests presented a tough task for simulation software (most commercial software cannot accurately simulate all these tests) and have provided an excellent benchmark for the PRODIES system. The use of tests known to the SME end user partners which produce specific known results will enhance the validity and general acceptance of the PRODIES system software by industry.

The proposers believe that the PRODIES system will mean a break through in the traditional experimentally based die design procedures. The PRODIES computer system will be used by SME's as a "virtual prototype testing laboratory" aiming at providing all the necessary information on the overall performance of new dies, thus allowing to introduce the necessary modifications in the die design prior to the manufacturing of any physical prototype. Considerable savings in the die design and manufacturing cycle will be achieved with the introduction of the sought computer-assisted procedure. In addition new and more optimised dies will be obtained at a cost affordable by standard SME's in the die manufacturing and sheet stamping sectors.

The participating SME's will exploit in house the new computer based system for enhanced die design and production. The PRODIES system itself will be marketed worldwide by QUANTECH with technical support from CIMNE. A marketable software product is expected to be released after twelve months of completion of the project.
The objective of this project is to develop and validate a computer system (the PRODIES system) that can be effectively used by SME's for design, manufacturing and quality assurance of sheet stamping dies. The sought PRODIES system will be based on an existing code, named STAMPACK, developed by CIMNE for sheet stamping analysis. The current version of STAMPACK includes unique capabilities, which make the code, as it is, competitive with existing sheet stamping software available in the market. Among these capabilities we can list the possibility for parallel computing in networks of PC operating in Windows, the capacity for performing elastic spring back analyses in a fast manner, the possibility of including draw beads in the analysis, the prediction of manufacturing defects and the integration of advanced pre and post processing facilities. The specific project objectives include the following: - Development and integration of material properties, defect prediction module and tool databases into the existing version of STAMPACK. - Enhancement of user's interfaces of STAMPACK following the specification of SME die manufacturers. -Development of the PRODIES computer system for die design in SME's running in parallel in PC networks under Windows. - Implementation of PRODIES system in the premises of the SME's participating in the project. Training of technical staff into the use of the code. - Experimental validation and feed back enhancement of the PRODIES system. - Specification of a computer based methodology for enhanced design and production of sheet stamping dies. The new PRODIES computer system will be used by SME's proposers as a virtual prototype testing laboratory aiming at providing all the necessary information on the overall performance of new dies, thus allowing to introduce the necessary modifications in the die design prior to the manufacturing of any physical prototype. Considerable savings in the die design and manufacturing cycle can be achieved with the introduction of the sought computer assisted procedure. In addition new and more optimized dies can be obtained at a cost affordable by standard SME's in the die manufacturing and sheet stamping sectors.


Following the succesful development of the project the participating SME's will exploit in house the new computer based system for enhanced die design and production. The PRODIES system itself will be marketed worldwide by QUANTECH with technical support from CIMNE. A marketable software product is expected to be realised after eighteen months of completion of the project.

Funding Scheme

CRS - Cooperative research contracts

Coordinator

Decad Ingenieria Integral, S.A.
Address
C/sancho De Avilla 52-58
8018 Barcelona
Spain

Participants (10)

FUNDACION ASCAMM
Spain
Address
Av. Universitat Autónoma 23 Parc Tecnológic Del Va
08290 Cerdanyola Del Valles
Fischer Werkzeug und Maschinenbau GmbH
Germany
Address
Elsässer Str. 6
79346 Endingen
INTERNATIONAL CENTRE FOR NUMERICAL METHODS IN ENGINEERING
Spain
Address
S/n,gran Capitan S/n, Campus Norte Upc, Edificio C1
08034 Barcelona
Manshadi & Kolev Umformtechnik "Makum" GbR
Germany
Address
Im Horben 18
71560 Sulzbach An Der Murr
QUANTECH ATZ, S.A.
Spain
Address
S/n,calle Jordi Girona Salgado, S/n - Edificio Nexus
08034 Barcelona
Sociedad Industrial de Matriceria, S.A.
Spain
Address
Avda. Can Sucarrats 88
8191 Rubi
Talleres Rigol, SA
Spain
Address
Avda. Maresma 85-91
8918 Badalona
Tecnirolo - Tecnologia Informática e Aplicaçoes CAD/CAM Lda
Portugal
Address
Urbanizaçao Quinta Da Maligueira Ap 393
2404 Leiria
ZENTRUM FERTIGUNGSTECHNIK STUTTGART
Germany
Address
15,Nobelstrasse 15
70569 Stuttgart
diseços, Estillos y Fabricados especiales, S.L.
Spain
Address
C/ Bernat Metge 2
8205 Sabadell