Today, we would like to introduce CADmeister’s FORM-EX, a Springback Compensation support function.
~ Current Challenges in Press Die Design ~
In recent years, automotive die design departments have been facing increasing challenges with Springback Compensation and surface correction.
1) Main Requirements in Modern Die Design
- Support for ultra high-strength steel (UHSS)
- Weight reduction
- Higher accuracy
- Shorter lead time
2) Current Problems with Springback Compensation
- Work depends heavily on experienced engineers
- Surface correction takes a lot of time
- More die tryout loops are needed
- Surface quality varies by operator
3) FORM-EX helps customers achieve
FORM-EX uses forming simulation data, 3D measurement data, and tryout results to create accurate Compensation surfaces on CAD models.
- Reduced modeling work
- Better surface quality
- Shorter lead times
- Less dependence on individual skills
What is FORM-EX?:
* FORM-EX is a function that helps improve Compensation surface modeling work required in press die design.
- Specialized Functions for Compensation Modeling:
- FORM-EX provides dedicated functions that allow engineers to create Compensation shapes exactly as they imagine
- Integration with Forming Simulation Software:
- FORM-EX uses STL data from forming simulation results and deforms CAD data while maintaining material line length.
- Integration with Reverse Engineering Workflows:
- FORM-EX also uses STL data from measurement results and deforms CAD surfaces with high fitting accuracy
* FORM-EX utilizes forming simulation STL data, 3D measurement data, and actual tryout results to apply highly accurate Compensation deformation to CAD surfaces.
- Reduce modeling workload
- Improve surface quality
- Shorten lead times
- Reduce dependence on individual skills
1. Make Springback Compensation more efficient
We spend a lot of time modifying surfaces for Springback Compensation.
FORM-EX helps standardize and improve Compensation deformation work on CAD surfaces that previously depended on engineer experience.
For example, the following functions help users achieve stable quality more easily:
- Automatic hole filling
- STL data utilization
- Automatic deformation functions
Even complex deformation such as twisting can be handled while maintaining smooth surface quality.
2. High-Accuracy Modeling Using STL Data
It takes a long time to remodel target shapes from measurement data.
Also, modeling quality depends on the engineer, so experienced engineers tend to become overloaded.
FORM-EX provides both “STL Compensation Morphing” and “STL Fitting Deformation” functions using STL data.
By using STL data captured from 3D measurement systems, FORM-EX can:
- Reflect deviation data onto CAD surfaces
- Fit CAD surfaces directly to STL data
This allows highly accurate Compensation surfaces to be created in a short time.
As a result, reverse engineering work can be greatly reduced.
1) STL Compensation Morphing
- FORM-EX uses STL data exported from forming simulation software and reflects deformation differences onto CAD surface.
- This makes it possible to create Compensation shapes that consider springback behavior.
2) STL Fitting Deformation
- CAD surfaces can be fitted directly to STL data obtained from 3D measurement systems.
- This enables highly accurate CAD surface generation based on actual measurement results.
3) Global Deformation
- FORM-EX supports deformation adjustment through:
- Point and curve control
- Numerical input
- Tryout-based fine tuning is also possible.
4) Support for Design Changes
- Existing Compensation deformation data can be reapplied even after CAD design changes.
- This helps reduce engineering work during design revisions.
Who is FORM-EX for?
- Spend too much time on Springback Compensation
- Have increased workload due to Support for ultra high-strength steel (UHSS) forming
- Want to improve reverse engineering efficiency
- Want more stable surface quality
- Want to reduce dependence on experienced engineers
- Want to reduce die tryout loops
- Want to shorten die manufacturing lead times
Benefits
- Reduced modeling workload
- Improved surface quality
- Shorter lead times
- Reduced dependence on individual skills
FORM-EX is a practical solution that improves die design and modeling work by using simulation data, measurement data, and shop-floor know-how.
FORM-EX looks very helpful for developing new engineers and transferring technical skills to the next generation
