AutoForm-HemPlanner^plus R7 in Hemming Simulation

www.autoform.com

AutoForm-HemPlannerplus

Information Package - R7

Content

Hemming Processes

• Roll Hemming

• Die / Table Top Hemming

Potentials for Process Re-engineering

Direct Benefits

• Quick Hemming

• Advanced Hemming

Proposed Application Use Cases• Planning

• Forming and Cutting Tool Design

• Hemming-Device Design

AutoForm-HemPlannerplus R7• Integration into the AutoFormplus GUI - Die Stage

• Unfold Option for Part Flanges

• Spring Controlled Roller / Springback Assembly / Flexible Inner

• Evaluation Stage


Hemming Processes - Principle

• Hemming operation is typically used to join inner and outer panels together

A

Inner part

Outer part

A

I

View I

Pre-hemming

Final hemming

Die

Tool surface

Outer sheet

Tool surface


Hemming Processes - Principle

To start the interactive presentation please click here,

download and initialization can take a few seconds!

Download of Adobe Acrobat Reader DC - here!


http://www.autoform.com/download/HemPlanner/PDF3D/AFHemPlanner_IP_3DPDF_1.pdf

http://10.113.201.77/en/hemming_170110.html

• Features:• Flexible, various components can be hemmed in a

single cell

• Requires less tooling

• Ideal for low and medium volume production

• Disadvantages:• Relatively slow process

Hemming Processes - Roll Hemming

Roller trajectory

Roller


Hemming Processes - Roll Hemming







Hemming Processes - Die Hemming

• Features:

• Traditional way for high volume production

• Complete hemming can be done in one station

• Suitable for large panels

• High degree of automation

• Disadvantages:

• High cost

• Restricted to simple panels


• Features:• Hemming is done using vertical, horizontal

or circular movement or a combination of these movements

• Suitable for medium and high production volumes

• High hemming quality

• Disadvantages:• High cost

• Dedicated to one specific panel

Hemming Processes - Table-Top Hemming


Hemming Processes – Die / Table-Top Hemming







Content


Hemming Processes

• Roll Hemming



Direct Benefits

• Quick Hemming









Potentials for Process Re-engineering - Quick vs. Advanced Hemming

Part ProductionConcept, Styling Product Design Production Planning Process Engineering TryoutTool Design andManufacturing

Process Maturity10% 25% 50% 75% 90% 95%

Feasible Part Design

Process Design

Tryout Support

Press ShopSupport

Process Engineering

Preliminary Part Releasefor Planning and Draw-OP Engineering

Process Plan Releasefor Process Engineering

Draw-OP and Final Part Releasefor Process Design

Die Layout Release for Process Design

Process Design Releasefor Milling

Tool Buy-Offfor Part Production

Tasks

Planning / Purchasing / Bidding

Function

Cost

Lead Time

Quality

Decision Drivers


Quick Hemming:

• Perform analysis of part geometry

• Eliminate hemming defects

• Choose hemming technology and develop hemming plan

• Estimate space requirements, production resources and type of manufacturing equipment

Advanced Hemming:

• Ensure problem-free production

• Validate the hemming process - as is die/trim

• Compensate material roll-in

• Prepare support information for further development stages

Draw-OP Engineering /Advanced Feasibility

Potentials for Process Re-engineering - Current State



Process Design


Tryout Support

Press ShopSupport

Process Engineering







Tasks


Hem & Assembly Design

Hem & Assembly ToolingMethod Planning

Robotics and Assembly Automation Design/Fixtures

Hem Tool Tryout Support

Generic Rules of Thumb, Personal Experiences, Standards

Single Part Level (CAE)

Assembly Level (no CAE)




Process Design


Tryout Support

Press ShopSupport

Process Engineering







Tasks









Mismatch

Corrective ActionsCorrective Actions

Co

rrectiveA

ction

s

Co

rrectiveA

ction

s




Process Design


Tryout Support

Press ShopSupport

Process Engineering







Tasks









Mismatch

Corrective Actions




Process Design


Tryout Support

Press ShopSupport

Process Engineering







Tasks









Potentials for Process Re-engineering – AutoForm Approach



Process Design


Tryout Support

Press ShopSupport

Process Engineering







Tasks






Quick H – Concept


Assembly Level (AutoForm-HemPlannerplus)

AH - Validation

Content


Hemming Processes

• Roll Hemming



Direct Benefits

• Quick Hemming









Direct Benefits - Quick Hemming Single Part


• Flanged part geometry

• Hemmed part geometry

• Optimized trim line

• Hemming concept

• # tools - complexity, shapes, measures

• Invest, handling/manufacturing time

• Logistics, capacity

• Surface draw panel

• Compensated hemming induced side-effects

• Detailed flange design

• Trim-line, notches

• Validated clamping concept - position, forces




Process Engineering


• Hemming strategy - steels, rollers

• # tools, size, shape

• Wrinkles/splits at free edges

• Wrinkles/splits bend line

• Roller trajectories

• Positions/forces clamping set-up

• Hemming bed designs

• Final setting validation

Direct Benefits - Quick Hemming Assembly


Assembly Level (CAE)




Direct Benefits - Advanced Hemming


• Validated draw panel

• Springback considering pre-tensions from forming

• Compensation

• Validation of trim-line and flange design

• Clamping set-up

• Validated trajectories

• Validated clamping set-up

• Validated springback

• Compensated assembly

Assembly Level (CAE)Robotics and Assembly Automation Design/Fixtures

Single Part Level (CAE)Draw-OP Engineering /Advanced Feasibility

Process Engineering

Target edge

Hemmed part

Optimised cutting curve

Content


Hemming Processes

• Roll Hemming



Direct Benefits

• Quick Hemming









+-

Technical deviation from reference part and

final single part and assembly

Proposed Application Use Cases - Planning


Estimated invest based on reference parts

Final invest single part & assembly

Optimization approach: AutoForm-HemPlannerplus

Deviation in cost documentation of reference part -Benchmark-parts of other business units and companies

Deviation from evaluation of the current market situation of the tool shops and their pricing

Proposed Application Use Cases - Draw and Trim Die Optimization

Roll-hemming Table-top / die hemming Predicted springback in assembly

• Early draw-die-contour and trim lines - springback driven

• Early draw-die-contour and trim lines - flange design

Trim-line Flange behavior


Proposed Application Use Cases - Hemming Device Design


• Springback as a result of hemming strategy

• Shape - bed/rollers/steels

• Position/forces - clamps

• …

• Roller trajectories

• Roller speed

• …

1

2

Proposed Application Use Cases - Organization

Data transfer

*.asm

OEM - environment

OEM - environment TIER 1 - environment


Content


Hemming Processes

• Roll Hemming



Direct Benefits

• Quick Hemming









• Full integration in AutoFormplus GUI process plan

• DieStage for AF-HemPlanner feature generation

• Optional import of tool surfaces (bed/roller/steel) and trajectories from CAD supported

AutoForm-HemPlannerplus R7 – Integration GUI R7


• Starting point is an imported part geometry

• Several parameters for unfolding can be used

AutoForm-HemPlannerplus R7 - Unfold Option for Part Flanges


AutoForm-HemPlannerplus R7 - Spring-Controlled Roller/Springback


Glue on both sides

• Spring controlled - force [kN]

• Fixed springback

• Free springback

AutoForm-HemPlannerplus R7 - Evaluation Stage


Result variables:

• Hemming Thickness

• Hemming Roll-in

• Hemming Deviation

Thank you!


AutoForm Engineering B.V.Industrieweg 2, 9th FloorNL-2921 LB Krimpen a/d IJssel

+31 180 668 255

AutoForm-HemPlanner^plus R7 in Hemming Simulation

Automotive

Transcript of AutoForm-HemPlanner^plus R7 in Hemming Simulation