Cameron Tool, located in Lansing, Michigan, is situated between Grand Rapids and Detroit. Consequently, its primary source of projects is the automotive sector, although it also caters to other industries. With a workforce of about 80 employees, the company specializes in progressive and transfer stamping dies that produce a broad range of part geometries such as crossmembers, heat shields, and smaller inner bracket parts.
On the front lines of the company’s technical operations, their simulation feasibility experts, are responsible for evaluating all parts and projects submitted to Cameron Tool for manufacturing. The primary role is to ensure that all components are produced with maximum cost efficiency and precision, as allowed by the manufacturing process. Collaboration with the product engineering team to identify the optimal design process for manufacturability, while continuously striving to enhance the production process is required.
Their workflow has experienced a notable enhancement in both accuracy and speed since they integrated the AutoForm DieDesigner®Plus module. This integration has enabled Cameron Tool to gain a competitive advantage in the automotive tooling industry. In this case study, we’ll examine how Cameron Tool, a midsized tool shop, utilized this new capability from AutoForm to enhance the efficiency of their simulation feasibility processes.
The Role of Simulation Feasibility at Cameron Tool
Their involvement begins at the process and design stage. Coordination’s with the engineering team to identify potential design modifications that can enhance manufacturability process without compromising functionality. Additionally, they collaborate with customers to develop viable solutions to potential issues identified through simulation. This role requires them to swiftly identify solutions that would benefit all stakeholders.
They also perform feasibility verification for parts that have not yet been awarded to Cameron Tool. In these instances, the constraints of time and financial resources can make it challenging to complete the task quickly and accurately.
To conduct the final validation simulations, they previously used the method which involved using CAD software (NX) for processing layout modifications, followed by AutoForm for simulation. To complete the part process layouts between the two platforms, it’s required to import and export them after each change. While this process is effective for simple components, it becomes increasingly inefficient and time-consuming as designs grow more complex.
They discuss the challenges associated with this dual-platform approach, emphasizing the potential loss of geometry quality and the necessity of re-doing surface areas during import and export operations.
Speeding Up the Design Process
Automotive manufacturing has become increasingly time-sensitive over the years. The introduction of DieDesigner®Plus can significantly reduce the time required to create and finalize the design processing stage. For complex components, Cameron Tool reports that the time has decreased from weeks to just a few days. This improvement in efficiency is primarily attributed to the module’s capability to refine design process internally, ensuring they meet formability and compensation requirements.
The key advantage has been the elimination of the time-consuming import-export steps. Instead of creating a preform in a separate CAD software and then exporting for use in AutoForm, they can now complete the entire process within the AutoForm software. This streamlined method also allows them to concentrate more on the practical aspects of the design process, such as creating the optimal shape for forming rather than nominal shapes that may not be suitable.
Moreover, they can apply a larger number of design ideas in a shorter timeframe. And they can make immediate adjustments and rerun simulations to enhance formability and address issues without losing any data. This ability to iterate rapidly has led to improved outcomes and increased overall efficiency.
The Real-World Impact: Aluminum C-Pillars and Other Complex Parts
Jake Darling, at Cameron Tool, used this new workflow to produce the manufacturing process on an aluminum C-pillar, a deep-drawn component situated above the rear door that connects the car’s roof to the body on each side. With a draw depth of 5.5” or 140mm and the inherent challenges associated with forming aluminum, this presented complex problems to address.
“In the past, I had to develop the process in CAD and then export it to AutoForm for process validation. I needed to alternate between CAD and AutoForm multiple times, adjusting and then re-running the simulation in AutoForm to have the new results.”
Jake Darling
According to Jake, with the new workflow, he was able to make these adjustments directly within AutoForm and re-run the simulation without risking data loss during migration between systems. He was able to modify design parameters, such as the radius size of the bead or the addendum blend, all within AutoForm. After these adjustments, the surface data can be directly exported for machining, with the expectation that the connectivity and the tangency of the surfaces are well maintained for manufacturing use.
The image below shows geometry creation functionality, that Jake talks about:
In conclusion, Jake effectively balanced compression and thinning issues, creating a final design that was both feasible and optimized for manufacturing. These workflow adjustments were crucial in meeting tight deadlines and delivering a high-quality final product.
The adoption of tools like DieDesigner®Plus has enabled Cameron Tool to better serve its clients. They can now more effectively manage complex components, such as those made from aluminum for electric vehicles (EVs), more effectively. This advancement has provided them with a competitive edge in an industry that is increasingly shifting towards lightweight materials and advanced manufacturing techniques. Currently, Cameron Tool primarily collaborates with tier-1 suppliers. However, they are optimistic that they will soon secure a greater number of projects and work directly with automakers.
Conclusion: Efficiency and Innovation in Manufacturing
To summarize, the ability to remain in one software package can transform how engineers, such as Jake, approach design process layout and simulation validation more effectively. By working within a single environment, engineers can save time, maintain the quality of geometry, prevent data loss, and explore more innovative solutions.
The new process has saved both time and money while delivering a higher quality product. As the automotive industry continues to evolve, tools such as DieDesigner®Plus are poised to play a crucial role in helping companies like Cameron Tool remain competitive in a challenging market.
