Full Cycle Simulation, Virtual Tryout and Reality Check

Full Process Simulation is the Simulation on all line dies (all nominal design dies) with formability results and final springback results at the end of the line. Full Cycle Simulation is the Simulation on all line dies (all compensated dies) with formability and springback results on panels from each operation. The final operation panel must meet the GD&T tolerance requirements. The final surface quality must meet the NC programming quality requirements. The operation panels must meet nesting/fitting tolerance requirements. This full process full cycle simulations presented tremendous challenges to Chrysler stamping simulation engineers. In Chrysler, we did full process full cycle simulation on all of our in house stamping line dies, hoping that we will achieve significant improvement in our stamping dimensional quality. The reality is a vailable now to be shared with the stamping simulation community. In this presentation, a typical full cycle simulation flow is included to show how the virtual tryout is iteratively performed to achieve dimensional accuracy. CMM data are collected after real tryout and summary of the CMM data is included to show the reality check. Room for improvement is obvious after reviewing the reality check.