Automated Press Die Shape Creation Using Pre-stored Processing Data
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Solution Overview
Problem
Current systems struggle to automatically create press die shapes for various pressing processes and product shapes, particularly failing to account for blank holder portions and requiring significant engineering expertise and time, especially when dealing with forming (bending) and drawing processes with or without pads.
Innovation Solution
A system and program that automatically generate press die shapes by utilizing product shape data, part processing method data, and feature identification to create press die shape data, including blank holder and addendum surfaces, based on categorized press die shape types, such as product extension and blank holder and addendum surface creation types, using devices like press die outline creation, punch opening line determination, and pad dividing line creation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an engineer designs a press die from scratch using CAD data specifying product shape, then the press die shape can be customized to produce formed products with good quality, but it takes a lot of time and effort for creating surfaces and adding fillets
Solution Approach 1:
The system pre-stores processing method data (including press die shape types, pressing methods, and feature identification criteria) for ordinary parts in a database. When designing a new press die, the system automatically retrieves and applies relevant pre-stored data based on product shape features, eliminating the need to create press die shapes from scratch and significantly reducing design time while maintaining quality
Solution Approach 2:
The system creates press die shapes by automatically generating and copying proven design patterns from the database based on product shape features. Instead of manual CAD operations, the system replicates successful press die configurations for similar products, ensuring quality while reducing design time and effort
2Ease of operation
If an engineer without sufficient knowhow designs a press die, then the design process can be initiated without experience, but correction of press die shape based on simulation results must be repeated requiring many works and man hours
Solution Approach 1:
The system performs automatic press forming simulation using the generated press die shape and product shape data. When defects like wrinkles or cracks are detected in the simulation results, the system automatically identifies the problematic regions and corrects the press die shape by modifying relevant surfaces or adding features, then re-simulates to verify the correction. This automated feedback loop eliminates the need for repeated manual corrections by engineers
Solution Approach 2:
The system autonomously performs the complete design-correct-verify cycle without requiring expert engineer intervention. The automatic simulation and correction functionality enables the system to self-validate and self-improve the press die design, making professional-grade press die design accessible to users without extensive knowhow while eliminating time-consuming iterative corrections
3Loss of time
If existing systems create press die shapes automatically, then design time is reduced, but they fail to account for blank holder portions and various pressing processes
Solution Approach 1:
The system stores diverse processing method data for ordinary parts covering multiple pressing processes (forming/bending with or without pads, drawing with or without blank holders) in the database. The automatic creation functionality adapts to different product shapes and pressing process requirements by selecting appropriate pre-stored data, enabling versatile press die design across various processes while maintaining efficiency
Solution Approach 2:
The system automatically adjusts press die shape parameters based on the identified pressing process type. When creating press die shapes for different processes (e.g., forming vs. drawing, with or without pads/blank holders), the system modifies relevant geometric parameters and structural features according to the specific process requirements, ensuring both efficiency and process-appropriate design
Data Source
AI summary
The present application automatically creates a press die shape corresponding to various kinds of pressing methods and product shapes using a part processing method data relating to press forming of ordinary parts. It includes a data storing device which stores a data relating to a shape of a part; a pressing method for press forming the part; a pressing direction setting and a press die shape type, with respect to each part; a part processing obtaining device which obtains a data relating to the pressing method of a referencing part, the pressing direction setting and the press die shape type; and a creation device which creates the press die shape data relating to a shape of a product portion and a peripheral portion thereof in the press die, and the pressing method, the pressing direction setting and the press die shape type of the referencing part.