Our company, PWO Czech Republic, specializes in stamping parts and manufacturing associated tools. For many years, we have built our reputation on a high level of innovation and technological excellence. We focus not only on producing the tools themselves but also on optimizing our processes through sophisticated simulations. Our goal is to ensure maximum precision from the initial design stages through to mass production. This article introduces some of the major innovations we have integrated into our processes.
Stability from Initial Design to Mass Production
We guarantee that all inputs to our simulations are based on the actual condition of the tools, ensuring the reliability of the parts produced. The precision of the overall structure, combined with meticulous CAD surface definitions, exact manufacturing, consistent machining of surfaces, precise tooling treatments, and accurate descriptions of the materials’ mechanical properties, ensures our simulations match real-world outcomes. Our principle—”an exact input results in an exact output”—minimizes deviations between simulations and actual parts, thus maintaining the high quality of our products.
Springback of the A-Pillar Part
Fig. 01 Original state: Point A shows springback during the initial production stage without internal simulation improvements.
The example of the A-pillar illustrates the progress made in our tool design process. The initial simulation resulted in point A, where the springback of the actual sheet was outside the specified tolerances. This was due to incomplete tooling surface descriptions, material variability, insufficient simulation details, and incomplete real-world data at the initial simulation phase. As a result, the simulation failed to accurately predict the stamping behavior, causing some parts to deform beyond the permitted limits and requiring frequent modifications, prolonging the production cycle and increasing repair costs.
After a thorough analysis, we implemented several optimization measures, including accurately defining pressure distribution (and gas springs), refining geometrical draw-beads and friction parameters, employing accurate material models and cards, using advanced simulation tools, and selecting appropriate clamping concepts. These improvements brought us to point B.
Fig. 02 State after initial stamping: Springback at point B is within tolerances, thanks to enhanced simulation accuracy.
At this stage, the springback of stamped parts is within required tolerances, ensuring the parts meet structural and functional requirements without further adjustments after stamping. This advancement improved the final product quality and streamlined the entire manufacturing process. We have prevented excessive tool wear and reduced defective parts, maintaining stable and efficient mass production.
Fig. 03 Collaborating with AutoForm representatives at PWO, preparing a resin replica and subsequently scanning tool impressions to measure surface roughness.
Fig. 04 The PWO principle: An accurate input yields an accurate output.
Conclusion: Innovation and Quality as the Formula for Success
Our company remains dedicated to upholding the highest standards in stamping and tool design. Through precise simulations, stable manufacturing processes, and continuous innovation, we produce components that meet the automotive industry’s stringent requirements for precision, safety, and quality. Our pursuit of perfection is ongoing, continuously evolving with new materials, innovative manufacturing techniques, and advanced simulations to meet technological advancements and exceed customer expectations.
Fig. 05 PWO Czech Republic, a.s.
