Die Making Optimizing

Die Making Optimization Methodology
1. Identify the best process and flow
2. Implement 3-D design and manufacturing
3. Implement High Performance Machine and Tool

1. Identify the best process and flow

• Analyzing the formability of the material early in the development

cycle to allow for product design optimization.

• Predicting metal flow during the stamping process.
• Determining the final dimensions of the stamped part.
• Preventing flow induced defects such as excessive thinning of

material and wrinkling.

• Reducing amount of scrap material.
• Increasing die life.
• Use software for optimize design like DIESTAMP, FAST BLANK,

FASTFORM etc.

2. Implement 3-D design and manufacturing

































With Curvature radius analysis we can determine cutting tool we used
in machining process so all surfaces can be cut perfectly.

Press Part Example










Modification on dies is needed as drawing
specification. Dies must have additional radii for material spring in.



3. Implement high performance machine and tool

As we can see this graphic, "Processing costs" have highest initial cost

that need cost down.
Usage of machine and tool effectively can achive with the formula below :

After that we can create some simulation from machining software with

various cutting strategy to get quality and machining time as fast as

possible relate to the machining cost effeciency.

Machining time can be observed everytime we run a simulation.
Conclusion :

There are some problem that may appear in case doing the machining
process from a design part.

1. Process translate or converte from customer's drawing file to another
CAD software or CAM software, it can happened format distortion or
interference format on surface part.
CAM software read all surface contour into G-code/cutting movement
on machine, hence many case the result from process machining did not
macth with the original drawing or design.
2. So that all surface can be machined all surface contour must known
by CAM operator to determine tool usage.

If surface contour can not known than surface contour is not cut perfectly
that in conventional technnic depend mostly in die spotting/die setting
machine to cu manually by portable grinding tool or files or another
equipment.
Today mostly CAD/CAM software already adopted all above features.
The difference only in display and familiar icon to access that features.