We are pleased to announce the introduction of yet another sector to our business. Virtual Tool making, simulation is a term sometimes used, we can include so much more than just simulation, predicted tool life, coating processes, die face machining data and correct process engineering it is “Virtual Tool Making”
Manufacturing companies worldwide are looking to introduce new models more quickly than ever before. This can be witnessed by the new models being introduced by the Car manufacturers. Shorter lead times on new models keep designs up to date and sales volumes high. However, shorter lead times place their own pressures on toolmakers, as a large part of the tool making is development.
Following the initial tool design, machining of the forming stages of the tool begins. Upon completion of the machining, the tool is then assembled. Following assembly, the tool is trialled with laser cut profiles and inspected. Seldom, does the part produced conform to the component drawing. Modifications to the tool and its component parts commences at this point. This is the development stage, which is very time consuming and labour intensive. Experience plays a major part in the design process but it still relies heavily on trial and error.
Motorists worldwide are looking for more economical vehicles due to ever increasing fuel costs. More economical engines are being introduced. However, economical engines become more beneficial if the overall weight of the vehicle is reduced. Weight reduction must be achieved without compromising safety. The use of Aluminium is becoming more common place, as is thinner section alloyed steels with higher yield and tensile strengths. These new materials and particularly their mechanical characteristics are providing new challenges to Toolmakers. Splitting, creasing, cracking and “spring back” issues are common place due to the materials having less formability.
To allow us to meet the reduced delivery times with difficult to form materials, Lodent Precision has introduced a “Virtual Tool Making” service. This service allows Lodent to offer complete “Process Engineering.” We define a forming process, then run simulation until we have a green part, calculate the most efficient material yield optimisation, we even provide spring back analysis and compensation if required. The use of “Virtual Tool Making” will give us the best chance of meeting tight delivery times commented Paul Riley a Director at Lodent. Development time after producing the forming stages of the die can be considerable. By completing the “Virtual Tool Making” process up front we plan to reduce this development time. Another benefit of the process is our ability to quote more accurately and even prove to our customer that it is feasible to produce the part to the current design before we begin to cut metal.
After spending all of my working life, close to 35 years now, in Press working and metal forming industries, I see “Virtual Tool Making” as the biggest technical advancement I have witnessed, which includes CAD/CAM, CNC machining and Wire erosion. I am looking forward to seeing this facility blossom concluded Paul.