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Sheet Metal Part Feasibility

The PE division has an experienced team to execute virtual stamping try-out with PAMSTAMP and one step simulation modules like FTI.

Salient features are as follows:

  • Method Plan in 3D

    Sheet Metal Part Feasibility
  • DFM Review by Macro-Feasibility: Experienced engineers provide valuable feedback prior to simulation by visually reviewing panel CAD data. Feedback related to improving trimming condition for higher steel life, increasing material yield, part functional aspect and part shape (e.g. undercuts, abrupt geometry changes etc) are normally given.

  • One Step Simulation: Use of FTI one-step simulations to minimize Pam-stamp trials.

    Forming Simulation
  • Micro-feasibility: Virtual tryout for draw operation is simulated using Pam stamp. wrinkles prediction, thickness distribution, spring-back trends, FLD circle grid analysis, strain distribution analysis, Shock line / Skid Line / Draw-in prediction is possible. A number of iterations are done with intermediate drawn part modification until satisfactory results are obtained.
  • Process Simulation for all subsequent Forming Operations: Simulating Restrike, Flange and Cam forming enables capturing of deformation occurring in post draw operation and soft condition verification of trim line.

    Process Simulation
  • Complete Process Simulation: Identifying the root cause of spring back so that compensation is added in appropriate die.

    Complete Process Simulation
  • Spring Back Correction through PS2G Die Compensation: Many times it is identified that spring compensation should be given in draw tool even before machining tools. Doing this is possible with PS2G software in certain cases when adjacent illustration clearly shows the comparison of actual and simulated Pam Stamp spring back and compensation done in Pam stamp.

    PS2G Die Compensation
  • Redesign: In case of critical panels that have noteworthy feasibility problems, the support of redesigning panels taking cognizance of vehicle level assembly and engineering constrains is an added advantage if products are ready for production due to feasibility study at the design phase itself.

Tool Design

PE manages tool design in 3D using CatiaV5 and Pro-E (especially for foundry tooling). Data management is through Teamcentre PLM. 3D visualization in ".jt" files format and large standards library.

Capability is offered to design following kinds of tools

  • Stamping Dies for Tandem Lines, Transfer Lines, High Speed Blanking Lines

    Stamping Dies
    Draw die for Panel Carrier Side Wall Outer of a Tata Public Transport Vehicle

    Flange and Restrike dies
    Flange C 'Flange and Restrike die for Panel Carrier Side Wall Outer of a Tata Public Transport Vehicle
  • Car Body (BIW) Welding Fixtures
    PE pioneers designing welding fixtures for main line sub-assemblies of BIW that are safe, modular and easy to manufacture

    Welding Fixture
    Sub Assembly Welding Fixture for Body Side of a Tata Pick up
  • BIW / Panel Piercing fixtures
    Some added holes require additional die stamping operation that cannot be accommodated in automated press line. Piercing tools for such add-on holes are needed many times for a short duration or for low volume requirement.
    PE can design piercing tools with Hydro-pneumatic systems that handle selectivity in pierced holes enabling multiple-variant management.

    Piercing Fixture
    Piercing Fixture for Body Side of a Tata Sedan Car
  • Frame (Chassis) Welding Fixtures

    Frame Welding Fixture
    Tack III Frame Welding Fixture (Arc-Welding) for a Tata SUV
  • Foundry Toolings for Grey Cast Iron and Aluminium

    Foundry Toolings
    Pattern for a Tata Engine Cylinder Head

    Core Drilling Fixtures
  • Special Purpose Foundry Tooling like Final Core Setting Fixtures, Core Drilling Fixtures etc.

    Special Purpose Foundry Tooling
    Final Core Setting Fixture

    Final Core Setting Fixture
    Mould Pack Designing in CATIA V5

Weld-shop process Engineering

  • PE masters the process engineering for welding of car bodies in all conceivable variants, from the smallest bracket to the complete body-in-white (BIW). Work includes defining the family tree for BIW, defining locating and clamping strategy and PLP co-ordination through stages, defining the sequence of loading parts assembled, and spot allocation to meet tack time. In executing this process the overall product quality is enhanced and an assembly process facilitates trouble free manufacturing.

    Frame Welding Process

    Weld-Shop Process Engineering

Weld-shop Feasibility

Sheet metal welding experts work extensively on feasibility of BIW welding.

Activities include-

  • Weld gun stimulation and collision checking using Delmia

    Weld Gun Stimulation
  • Studying from ergonomic perspective to enable ease of handling welding and safety.

    Ergonomic Perspective