3D Process / Method Design
“The Right Process, the Right Die Design”
The first prerequisite for success and trouble free production in sheet metal tooling is establishing the correct production methodology. In the 3D Process/Method Design phase, which follows immediately after feasibility studies, all manufacturing methods, operational steps, and station layouts from the raw material to the part’s final form are determined step by step.
At TKare Engineering, we carry out our 3D process designs with the utmost engineering discipline to minimize manufacturing losses to zero and achieve the most optimal die cost.
Advantages of 3D Process/Method Design
- Operation Count Optimization: By simulating the number of steps required for a part to achieve the target quality, unnecessary stations are eliminated; die size, weight, and cost are reduced.
- Minimum Scrap and Sheet Utilization Percentage: Maximum efficiency from sheet material is achieved by optimizing the part’s orientation on the line and the strip (layout) design.
- Real-Time Simulation Integration: Each designed process step (drawing, cutting, bending, straightening, etc.) is validated using formability simulations; springback and compensation surface calculations are completed during the process stage.
- Press and Automation-Compatible Method: The process design is structured by taking into account the technical capacity of the press line (Tandem, Transfer, or Progressive) where the project will be manufactured, as well as the operating curves of the transfer mechanisms.
TKare Engineering; provides high-precision sheet metal die design, simulation, and engineering solutions for the automotive, aerospace, defense, and home appliance industries.