As part of the development process for new stamping dies, in the automotive sheet metal forming (SMF) industry, the majority of all forming operations are simulated with the Finite Element Method (FEM) before the dies are manufactured. Today, these simulations are conducted with rigid tools under the assumption that there are no tool deformations. However, research shows that tool deformations have an influence on the finished product. In real production these deformations are compensated by manual rework during the try-out. Additional reason for simulating with rigid dies is that there are non-existing simulation methods elaborated for elastic stamping dies. Also, simulation of elastic tools requires high computational power.     Since simulations today are performed with rigid stamping dies the purpose of this work is to investigate the conditions of how to conduct SMF-simulations with elastic stamping dies. The object that will be studied is a stamping die for a Volvo XC90 inner door used in a single-action press. This work is part of the development to minimize the manual rework, with the goal to compensate for tool deformations in a virtual environment.    Results for rigid stamping dies in LS-Dyna was compared to currently used AutoForm as a pre-study. A simple model was then created to find a suitable method while using elastic stamping dies. The developed method was used for an industrial size stamping die.     Since there are little amount of research performed on simulations using elastic stamping dies, elasticity and complexity were gradually introduced into the FE-model. As a first step, only the punch was included as an elastic solid. Secondly, the die was added. Finally, the entire die was simulated as elastic together with the hydraulic cushion of the press. When the FE-model worked as expected a suitable method for minimizing the simulation time with acceptable results was studied.     Comparisons of measured- and simulation results show a high correlation. To improve the results from the FE-model factors such as press deformations, advanced friction models, etc. should be included.    Conclusions from this work shows that it is possible to perform SMF-simulations with elastic stamping dies. As the computational time normally is high this work also presents a method first step to reduce the computational time with acceptable results. Comparisons between simulations with rigid and elastic stamping dies proves that there are significant differences in the outcome of the two methods. / Reduced Lead Time through Advanced Die Structure Analysis - Vinnova

The competition in the car market in the world is continuously intensifying. To gain an advantage in the market while making a profit, each car manufacturer needs a strong focus on always improving in the technology development. It is not just technology of the cars that need development, but it is equally important to improve the manufacturing processes itself. In the end, this will result in more appealing products for the customer at a competitive cost. The aim and scope of this master thesis is to get a deeper understanding of the forces in the stamping die during sheet metal forming in manufacturing. By using strain gauges and microcontrollers, the forces during the entire forming process could be measured and analyzed. The relationship between the force on the pressure pins in the die and the length of the pressure pins was also investigated by adding shims on the pressure pins. A modular system using Arduino Uno with 3D-printed parts was developed to measure the forces in the blank holder during sheet metal forming. An Arduino software system and TeraTerm was found the most appropriate for collecting and organizing data from the strain gauge sensors and microcontrollers. Tests were then conducted using different settings of the press, and these showed that the forces in the blank holder were uneven. Adding shims to the pins so that they were all of equal length evened out the forces in the blank holder. Another test showed that adding more shims to only one of the pins increased the force in that pin, and that adding 0.5mm of shims to that pin more than doubled the maximum force. The system developed in this thesis can measure the forces in the blank holder during the sheet forming process at a lower speed of production. This system can also detect different force settings in the press. Lastly, it can also detect a difference in force for different pressure pin lengths. / Konkurrensen på bilmarknaden i världen intensifieras kontinuerligt. För att få en fördel påmarknaden samtidigt som de gör vinst måste varje biltillverkare ha ett starkt fokus på att alltid förbättrateknikutvecklingen. Det är inte bara bilens teknik som behöver utvecklas, utan det är lika viktigt attförbättra tillverkningsprocesserna i sig. I slutändan kommer detta att resultera i mer attraktiva produkterför kunden till ett konkurrenskraftigt pris. Syftet och omfattningen av detta examensarbete är att få en djupare förståelse av krafterna ipressverktyget under plåtformningprocessen. Genom att använda töjningsgivare och mikrokontrollerkunde krafterna under hela formningsprocessen mätas och analyseras. Förhållandet mellan kraften påmothållarpinnarna i verktyget och längden på pinnarna undersöktes också genom att lägga till shims påpinnarna. Ett modulsystem som använde Arduino Uno med 3D-printade delar utvecklades för att mätakrafterna i formen under formningsprocessen. Ett Arduino-mjukvarusystem och TeraTerm bedömdesvara det mest lämpliga för att samla in och organisera data från töjningssensorer och mikrokontroller. Tester genomfördes sedan med olika inställningar i pressen, och dessa visade att krafterna ipressverktyget var ojämna. Genom att lägga till shims på pinnarna så att de alla var lika långa utjämnadeskrafterna i pressverktyget. Ett annat test visade att genom att lägga till fler shims på endast en avmothållarpinnarna ökade kraften i pinnen. Genom att tillägg till 0,5 mm shims på den pinnen mer änfördubblade den maximala kraften. Systemet som utvecklats i denna rapport kan mäta krafterna i pressverktygets mothållarpinnarunder formningsprocessen vid en lägre produktionshastighet. Detta system kan också upptäcka olikakraftinställningar i pressen. Slutligen kan den också upptäcka skillnader i kraft vid olika längder påmothållarpinnarna.

Diploma thesis introduces the design of a functional part of a wine opener, focusing on simplicity and effectivity of the manufacturing process with the use of progressive stamping tool. The part will be made by technology of progressive cutting and bending. For the production of the specified part stainless steel coil marked as 17 241.4 will be used This material is suitable for the use in commercial gastronomy thanks to its qualities. Also in this thesis there are technical calculations, suggestios for of optimal tools, economic calculations, and technical-economic evaluation of the production of the specified part.

This thesis explains how to determine and eliminate the causes of quality problems in the production of connectors and small electronic components for the automotive industry. The process of making these components is carried out by use of both high speed and low speed metal stamping presses. There are descriptions of the different designs of editing punches, stamping dies, trimming and molding tools and how unplanned issues can occur during the production process. It addresses all the customer requirements for quality end products, listing the type of material, finishes and technology used for the production of individual components as well as their functionality, durability, and economic impacts. All examples of changes in the design or technology of metal stamping presses are based on many years of practical experience and most of them can be successfully applied in other similar type of instrument production.