Intelligent Die-Face Design using Morphing Technology
Background
- Automotive manufactures are facing challenges to reduce the lead time for product development to meet rapid changing market demands.
- In vehicle development, conventional Die-Face Engineering (DFE) requires lots of tryouts before a new die can be used in mass production.
- Similarities of parts commonly exist among product generations or in the same product family, which provides the possibility to make use of the existing tooling/die design for new part production.
- Morphing allows the possibility for the knowledge and experience learnt from the die-face design of one product (Generation i) to be mapped/morphed onto that for a new but similar product (Generation i+1).
Approach
- Part-to-part mapping function by geometry registration method
- Die-to-die morphing and springback compensation
- Formability prediction by the strain increment method
- Die addendum morphing by extrapolation of the morphing area of the part surface
- Morphing related boundary continuities and trim line detection
Objective
- Develop methodologies to expedite DFE process by integrating the information of new part (Gen i+1), existing part and die (Gen i) for new die design (Gen i+1)
Researchers
