ESI’s predictive simulation for automotive panels and developing new lightweight structures

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Car body panels can be simulated for stamping with Pam-Stamp

Looking to address the needs of OEMs and tier-suppliers in the automotive, aerospace and heavy industries, ESI’s Pam-Stamp aims to predicts the outcome of complete sheet metal forming processes.

For manufactures this should means saved time and cost throughout the entire product development cycle – from conceptual design to try-out and production. For tooling suppliers, it should enable production die engineering by providing predictive simulation to support the styling of outer panels and the development of new lightweight structural parts.

“Car manufacturers aim to shorten their development cycles, sometimes to under a year. As a result, it is essential to forming operation and tool design engineers to be assured of very high surface quality early in the tool development cycle,” explains Harald Porzner, ­ESI ­director of virtual manufacturing product management.
“Demand for accurate and defect free outer panels – especially with exciting stylings – has increased dramatically. Meeting that demand is even more challenging when using advanced material forming processes for structural parts. Reliable results in both cases depend on defining the tool geometry with great accuracy.”

The addition of Die Starter, a new technology to generate the die surfaces needed to create a part, ESI claims it is possible in the styling and design phase to generate fully automatically the die tools and to validate the forming results.

The same technology can also be used in the concept development phase to generate automatically a starting point for refined die face design; saving a lot of iterations.

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Pam-Stamp’s results can be transported to ESI Virtual Performance Solution so that product performance models properly reflect the “as manufactured” components.