Aligned with the slogan of GMTCK Die & Press, Bold Reformation Beyond Expectations, the Manufacturing Engineering Die Process Engineering Team has initiated bold reforms within the team and organization to advance new technologies and environments.
At GMTCK (General Motors Technical Center Korea), the ME Die Process Engineering Team respects colleagues and customers by providing engineering solutions and results that exceed expectations, growing into a team that inspires trust and admiration. Additionally, we strive to meet customer needs and drive innovation through digital processes, exploring a variety of approaches.
The automotive industry is making continuous efforts to achieve net-zero emissions and meet ESG standards. To support this, we need to establish more efficient processes through simplified and digitalized engineering workflows, optimize material yield to reduce costs, and improve plant operating time by reducing scrap rates and die modifications.
At the R11 Launching Event, AutoForm Korea presented a Robust Digital Process for Quality Loop Zero to a large audience of customers. Following this, our GMTCK ME Die Process Engineering Team launched the “Digital Engineering Continuity within One System” project with AutoForm Korea to realize the robust digital process, and we would like to share the achievements made so far.
Since 2023, GMTCK has been reviewing innovative improvements in the layout modeling process. Byongchan Ahn, an engineer from the GMTCK ME Die Process Engineering Team, modeled and analyzed the body side outer part using AutoForm’s new process design product, AutoForm-DieDesigner®Plus. As a key initiative for 2024, AutoForm Korea has planned to work closely with GMTCK to apply AutoForm-DieDesigner®Plus to layout surface modeling and execute compensation modeling. This effort will substantially reduce the need for data conversion to other software during modeling, analysis, and compensation, creating a One Tool System.
Figure 1: One Tool System: process improvement
Part 1: Robust Layout Process
AutoForm and GMTCK structures the Robust Digital Process Project in two stages:
- Robust Layout Process to improve the layout surface modeling process
- Robust Springback Compensation Process to improve the compensation methods and the compensation modeling process
The compensation modeling improvements will be covered in detail in Part 2.
Figure 2: Robust Digital Process kickoff meeting and process consulting
The objective of the Robust Layout Process project is to reduce modeling time and data conversion time by modeling directly in AutoForm. Although it was GMTCK’s first time using AutoForm following initial training, the team was able to model effectively thanks to AutoForm’s intuitive and user-friendly features. Engineers who had not previously done modeling were also able to participate and become proficient.
To improve modeling skills, AutoForm and GMTCK organized an event called the DieDesignerPlus Modeling Study Group. All GMTCK team members actively participated, exploring the level of modeling that could be applied to product modeling for existing vehicle projects. During this event, each engineer’s modeling methods were shared internally, and weekly technical meetings with AutoForm provided reviews and feedback on user techniques and improvement areas.
Figure 3: DDP Layout Modeling Study Group and DDP modeling training
AutoForm and GMTCK ran the Study Group for a month, after which they reviewed progress on the Robust Layout Modeling Process Project and discussed plans for the Robust Springback Compensation Process Project in a final meeting. During this event, the team summarized and shared technical support and requests related to using DieDesignerPlus.
Byongchan Ahn from GMTCK evaluated the Robust Layout Modeling Process Project, stating: “While there is a significant advantage in easy modeling, I believe improvements are needed. If DieDesignerPlus modeling is applied to the work process, modeling time can be reduced by approximately 22% compared to the existing process.”
AutoForm views this project as a success, enabling closer customer relationships through continuous communication and establishing mutually beneficial connections.
Figure 4: Final review meeting
Summary
GMTCK and AutoForm Korea continue to collaborate to improve processes. With the release of innovative products and methods from AutoForm, we are strengthening the CAD-quality modeling and the compensation aspect of the design process. This advancement will help realize a One Tool System, reducing transition time between analysis and CAD modeling and allowing more time for other essential work processes. Personnel who had not previously modeled are now able to contribute, and modeling time has been reduced by approximately 22% compared to the existing process. AutoForm remains dedicated to advancing digital development processes for stamping and Body-in-White by listening to customer needs and implementing new technology. Only time will reveal the further improvements and advancements AutoForm will bring to the industry.
In Part 2, we will introduce the Robust Compensation Process, detailing improvements in compensation modeling and sharing real-world applications of this process.
