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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Stamping Die Development

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
The Siemens Solution
A single system covering the entire die development process
No information lost in data translation, or time wasted in repair
Low IT costs (purchase, training, deployment)
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Outline -- Die Development Framework
Die
Planning
Part
Production
Part
Design
Try-Out
Die
Feasibility
Die design &
Validation
Die
Manufacturing
Product
Data
Formability
Analysis
Springback
Analysis
Die
Structure
Analysis
Inspection
Design
Correction
Part
Production
Die
Kinematics
Validation
Press
Line
Optim.
Part
Transfer
Optim.
Die
Layout
Primary
Try-out
Secondary
Try-out
DFM
Analysis
Springback
Modeling
Die Structure
Design
NC
Preparation
Die Face
Design
Die Face
Machining
2D
Machining
Page 4

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Outline -- Die Development Framework
Product
Data
Formability
Analysis
Springback
Analysis
Die
Structure
Analysis
Inspection
Design
Correction
Part
Production
Die
Kinematics
Validation
Press
Line
Optim.
Part
Transfer
Optim.
Die
Layout
Primary
Try-out
Die
Planning
Part
Production
Part
Design
Die
Feasibility
Die design &
Validation
Die
Manufacturing
Secondary
Try-out
DFM
Analysis
Springback
Modeling
Die Structure
Design
NC
Preparation
Die Face
Design
Die Face
Machining
2D
Machining
Try-Out
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Part Design
Current Capabilities
Part designed in NX or other CAD
systems
Many ways to import product data
(JT, IGES, STEP, etc.)
Extensive data quality checking
and healing functions
Tolerance adjustment
Remove tiny edges
Remove tiny faces
Detect sliver faces
Detect spikes and cuts

Customer Benefits
No data translation (if part designed in NX)
Easy import from other systems


Checking Tools
Part Design
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Design-for-Manufacturing (DFM) Analysis
Current Capabilities
Checks the manufacturability of a panel
during the design stage
Verifies draw, trim, pierce, and flange
criteria based on corporate standards
Feedback saved in part file for review by
product designers
The checks are available in Checkmate and
Die Engineering

Customer Value
Reduces checking effort
Identifies problems early, so reduces
rework in downstream processes

Trim Surface Angle Check
Page 7

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Outline -- Die Development Framework
Product
Data
Formability
Analysis
Springback
Analysis
Die
Structure
Analysis
Inspection
Design
Correction
Part
Production
Die
Kinematics
Validation
Press
Line
Optim.
Part
Transfer
Optim.
Die
Layout
Primary
Try-out
Die
Planning
Part
Production
Part
Design
Die
Feasibility
Die design &
Validation
Die
Manufacturing
Secondary
Try-out
DFM
Analysis
Springback
Modeling
Die Structure
Design
NC
Preparation
Die Face
Design
Die Face
Machining
2D
Machining
Try-Out
Page 8

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Die Planning - Layout
Current Capabilities in NX
Generates complete Die Operation Lineup (DOL) taking
manufacturing processing rules into account.
Built-in manufacturing process knowledge helps make
decisions about
Number of stations needed
Tipping angle of part
Type of cams and cam drives needed
Filling open areas (holes, cut-outs)
Dynamic draft and depth analysis
The operations are created in multiple part files as
needed
Option in trim task to allow retaining the scrap shape as
a sheet body for downstream scrap shed simulation

Customer Value
Visual display of manufacturing stages helps speed up
decision making
Associative links speed up response to product changes
Filling
Trimming
Flanging
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Part Transfer Optimization
Current Capabilities
Simulation of the part motion from
de-stacking through removal
Calculation of speeds & acceleration
Dynamic collision detection
Detection of suction cup problems
due to speed and acceleration
Programming of handling devices
Customer Value
Early detection of motion problems
Improved cycle times
Page 10

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Outline -- Die Development Framework
Product
Data
Formability
Analysis
Springback
Analysis
Die
Structure
Analysis
Inspection
Design
Correction
Part
Production
Die
Kinematics
Validation
Press
Line
Optim.
Part
Transfer
Optim.
Die
Layout
Primary
Try-out
Die
Planning
Part
Production
Part
Design
Die
Feasibility
Die design &
Validation
Die
Manufacturing
Secondary
Try-out
DFM
Analysis
Springback
Modeling
Die Structure
Design
NC
Preparation
Die Face
Design
Die Face
Machining
2D
Machining
Try-Out
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Binder & Addendum Modeling
Current Capabilities in NX
Create binder wrap
Create developable surface representing
shape of sheet metal after binder closes
Creation of planar, cylindrical and conical type of
surfaces through mono-arc
Addendum sections
Create sections to define the addendum
Parameters available for editing
Shape conforms to given constraints
Access to the standard sections through reuse library
Addendum surface
Create addendum surface based sections
Die Output Curves
Create accurate trim line
Draw Bead
Specialized functions to create beads
Access to the standard sections through reuse library
Customer Value
Specialized modeling tools allow rapid
construction of Die Face
Binder Creation
Plus
Punch Radius
Stretch Wall
Reverse Radius
Flat to Bead
Part
Addendum
Binder
Addendum Section
After Convert to Flat Arc
processing
Access to Reuse Library
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
One-Step Formability Analysis
Capabilities in NX
Quick early analysis of formability
Flatten sheet metal to a blank
All within NX -- no data translation
Shows thinning, stress, and strain
Predict springback and generate
analysis report
Associative to the product model
The springback results are directly fed to
die face deformation to compensate for
springback

Customer Value
Helps to reduce physical try-outs
Quick results allow iterative improvement


Thinning results
Stress results
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Connections to 3
rd
Party Solvers
ETA provides two products: Dynaform, which allows NX part files to be
opened directly without translation, and BSE in NX, which allows one step
analysis to be invoked directly from within NX.
Autoform offers the Autoform in UG product that is fully integrated in NX. Die
Engineering users may invoke the one-step or incremental analysis functions
directly from NX.
The results from Autoform (mesh data) can be directly used for global
morphing within NX (e.g. to accommodate die panel for springback)
Engineering Technology Associates
Autoform Inc.
Die Data from NX can be transferred to Pamstamp through IGES or STEP
Pamstamp
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Capabilities in NX
Several surface deformation functions
to compensate for springback.
Global Deformation
Overcrown to Point
Overcrown to Curve(s)
Wall Deformation
Flange Rotation
Match to Sheet
Radius Reduction

Customer Value
Specialised functions reduce the need for
time-consuming manual modeling methods
Maintains the original topology of the
geometries
Springback Compensation
Overcrown
Compensation to FE Mesh
Wall Deformation to
multiple target Curves
Radius Reduction
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Die Face Modification (e.g. Springback Comp.)
OverCrown Area
Overcrown Color Map
Original
Deformed
Original
Deformed
Wall Deformation Radius Reduction
Original
Deformed
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Radius Reduction
Capabilities in NX
Improved process workflow for radius reduction
Analyze the faces that fall within a user-
specified range of radius values.
The faces that are found may be assigned a
color or other attribute to allow easy selection
in other commands that request faces as
input.
The faces appear concave with respect to the
draw direction
The system select the faces automatically
based on the attributes and apply the
reduction with the given percentage value
Customer Value
Eliminate the need for manual method of
preparing geometries for the radius reduction
Improved productivity

Radius Reduction
Workflow
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Outline -- Die Development Framework
Product
Data
Formability
Analysis
Springback
Analysis
Die
Structure
Analysis
Inspection
Design
Correction
Part
Production
Die
Kinematics
Validation
Press
Line
Optim.
Part
Transfer
Optim.
Die
Layout
Primary
Try-out
Die
Planning
Part
Production
Part
Design
Die
Feasibility
Die design &
Validation
Die
Manufacturing
Secondary
Try-out
DFM
Analysis
Springback
Modeling
Die Structure
Design
NC
Preparation
Die Face
Design
Die Face
Machining
2D
Machining
Try-Out
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Die Structure Design
Capabilities in NX
Solid modeling of all die structures
draw, trim, and flange dies.
Trim Steel Assistants creates components
needed for trim stage in one step
Casting features created with few steps
Adds necessary machining information to
the die structure model (planar, holes, etc.)
New/revised dies created from the
existing die templates (NX WAVE)
Libraries of standard parts
Customer Value
Improves visualization & analysis --
allowing problems to be detected earlier
Modeling of die structures in 3D reduces
the need for drawings for downstream
Casting features
Completed Die Structure Design
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Die Structure Analysis
Capabilities in NX
Predict stress/strain/deflection
under the given forming load
Optimize die structures with
adequate stiffness evaluation

Customer Value
Helps reduce die weight
Allows study of alternative
materials for production dies

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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Die Kinematics Validation
Capabilities in NX
Check die assemblies for interference
Simulation includes press, die, and part
Cross bar, tri-axis and transfer press
models are supported
Tracking curve generation
Associative links to die design
Customer Value
Reduces the need for physical tryout
for the die sets in the target press line.
Integration with die design reduces
tedious data preparation work
Simulation can be performed early
in the planning stage

Collision Check During Simulation
Die Inner Collision and Interference Check
Page 21

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Outline -- Die Development Framework
Product
Data
Formability
Analysis
Springback
Analysis
Die
Structure
Analysis
Inspection
Design
Correction
Part
Production
Die
Kinematics
Validation
Press
Line
Optim.
Part
Transfer
Optim.
Die
Layout
Primary
Try-out
Die
Planning
Part
Production
Part
Design
Die
Feasibility
Die design &
Validation
Die
Manufacturing
Secondary
Try-out
DFM
Analysis
Springback
Modeling
Die Structure
Design
NC
Preparation
Die Face
Design
Die Face
Machining
2D
Machining
Try-Out
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
NC Preparation
Current Capability
Synchronous Technology
Radius reduction
Surface extension
Filling holes
Composite curves
Many offsetting functions
And much more

Customer Value
Modeling tools readily
within the same system
Associativity preserved
Synchronous Technology
Radius Reduction
Editing
without
history
Theoretical corner
Hole Fill
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
General NX CAM Capabilities
Current Capability
Broad capabilities in one system
2D machining for die structure
3D machining for die face
Associative links to design
Rich automation capabilities
Rich modeling capabilities
available for NC prep work
Highly realistic simulation
Customer Value
One system no data transfers
Associativity reduces rework effort
Automation reduces work, improves
standardization and process stability
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
2D Machining (Milling and Drilling)
Current Capability
Roughing -- cavity & pocket milling
Finishing -- planar, face, plunge milling
Drilling (manual or feature-based) holes
Automation based on machining knowledge
database, features, attributes, PMI
General Features
In-Process Workpiece (IPW)
Tool path Editor
Toolpath verification
Customer Value
Automation reduces work, improves
standardization and process stability
Planar Milling
Profile Milling
Page 25

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
3D Machining (Die Face Machining)
Current Capability
Roughing
Z-Level Roughing
Gap Machining
Finishing
Contouring
Flow Cut
3D Profiling
Streamline
General Features
Surface region (steep/none steep)
IPW based rest material machining
High Speed Machining
Holder recognition & collision avoidance
Synch point distribution

Customer Value
Shorter lead-time to start of machining
Longer tool life
Automated rest material recognition faster
programming and machining
Synchronized point distribution for better finish
Surface Machining
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved

Streamline-Based Finishing
Capability in NX
Streamline finishing pattern flows
naturally with part shape
Not constrained by surface topology

Customer Benefits
Excellent surface finish fewer
secondary clean-up operations required
Faster/easier programming
Streamline finishing
Traditional finishing
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Feature Based 2.5D Machining
Feature Recognition
+ PMI Data read
PMI data and features read
directly from 3D model

PMI data attached to
NX solid model

Cutting
Tool
Library
Advanced PMI driven
machining system
Automatic
Programming Engine
Machining
Knowledge
Database
?
?
?
?
?
Step 1
Step 2
Step 3
Step 4
Finishing step
Stock
Operations
PMI data influences the
selection of appropriate
machining process elements
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Machining simulation inside NX
Connection to controller logic makes simulation more realistic
Accurate detection of collisions and machine limit violations
Accurate prediction of cycle times
Integrated Controller Driven Simulation
Siemens Virtual NC
Controller Kernel
Sinumerik
VNCK
NX CAM
Characteristics of
real controller
Highly realistic
simulation
Increasing fidelity of simulation
Image
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2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Synchronized Point Distribution
Out of step points on
adjacent passes
Synchronized Point Distribution -
machine motion is consistent
for adjacent passes
Improved
surface
finish
Synchronized point distribution improves surface finish
Page 30

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Outline -- Die Development Framework
Product
Data
Formability
Analysis
Springback
Analysis
Die
Structure
Analysis
Inspection
Design
Correction
Part
Production
Die
Kinematics
Validation
Press
Line
Optim.
Part
Transfer
Optim.
Die
Layout
Primary
Try-out
Die
Planning
Part
Production
Part
Design
Try-Out
Die
Feasibility
Die design &
Validation
Die
Manufacturing
Secondary
Try-out
DFM
Analysis
Springback
Modeling
Die Structure
Design
NC
Preparation
Die Face
Design
Die Face
Machining
2D
Machining
Page 31

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Design Correction Process
Two possible approaches
Machine point cloud (facets)
Machine surfaces

Use approach #1 when
Point cloud is dense
Part has no small details
No modifications needed

Use approach #2 when
Die Face and Die structure Design
required to maintain the changes
being made at the manufacturing
Required to machine the die face
and Die Structure Design




Compensated
Facet Data
Compensate
facet data
Global
Deformation
Clean up
point cloud
Point cloud
Compensated
Surfaces
Inspection
(scanning)
Try-out
Die Face
Machining
Atos
Steinbichler
Cognitens
Remove noise
Fill holes


Page 32

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Outline -- Die Development Framework
Product
Data
Formability
Analysis
Springback
Analysis
Die
Structure
Analysis
Inspection
Design
Correction
Part
Production
Die
Kinematics
Validation
Press
Line
Optim.
Part
Transfer
Optim.
Die
Layout
Primary
Try-out
Die
Planning
Part
Production
Part
Design
Die
Feasibility
Die design &
Validation
Die
Manufacturing
Secondary
Try-out
DFM
Analysis
Springback
Modeling
Die Structure
Design
NC
Preparation
Die Face
Design
Die Face
Machining
2D
Machining
Try-Out
Page 33

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Press Line Simulation (PLS)
Current Capabilities
User specific virtual presslines
Off-line programming capabilities
Die validation and collision check
Simulations include
Part behavior during transfers
Clearance & interference
Die check, assembly volume
Dynamic force calculations
Automatic tooling placement
Customer Benefits
Discover problems earlier
Reduce try-out time
Reduced space requirements
Increased stroke rates
Blanking line
Press line
Roll feeder
Cutting press
Feeder
Transfer
Press
Page 34

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Die Duplication Process
Die Duplication often needed
for replication or repair
Two possible approaches
Machine point cloud (facets)
Machine surfaces
Use approach #1when
Point cloud is dense
Part has no small details
No modifications needed
Use approach #2 when
Point cloud not dense enough
Part has small details not
captured well in point cloud
Modifications needed

Facet Data
Cleaned up
facet data
NX Rapid
Surfacing
Clean up
point cloud
Point cloud

Surfaces
Scan original
die face
Die Face
Machining
Atos
Steinbichler
Cognitens
Remove noise
Fill holes


Facets
Page 35

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved
Summary
We have solutions to support the entire process in one system
Our solutions have been proven in production usage
We continue to invest in development in this area
We are ready to partner with you to support your implementation
Siemens PLM Software
Thank you!
www.siemens.com/plm

2009. Siemens Product Lifecycle Management Software Inc. All rights reserved