Outputs - practical data for your tooling project.

StampingSimulation.com can provide you with all the data you need to get started with your tooling project. The Online Quote System will ask you to choose from the following OUTPUTS that you would like provided as part of your SimulateLite or SimulateComplete job. Remember that the quality of what you provide us (inputs) always governs the accuracy of what we generate back.

Animation of tooling and blank forming:

This is a standard output that is always included with every simulation job. It shows how the simulation job was setup and what tooling surfaces were used to create the simulation.

To see an AVI example of this output, please visit the downloads page.

Material forming limit information:

This is a standard output that is always included with every simulation job, unless the customer decides it is "not required".

This output predicts common sheet metal defects such as SPLITS, EXCESSIVE THINNING and THICKENING (wrinkles). Also known as "formability", this output is very important when deciding if a sheet metal forming process is acceptable or not.

Generally speaking, for a perfect process, all important areas of the part should be in the SAFE zone (green). This means the metal has been stretched all over without wrinkles, however thinning has occurred and the percentage of material thinning should always be analyzed in conjunction with formability.

To see an AVI example of this output, please visit the downloads page.

Material thinning information:

This is a standard output that is always included with every simulation job, unless the customer decides it is "not required". It may not be included as an output if the formability result shows failure, since the material has thinned infinitely at the failure location.

This output predicts the expected amount of thinning (and thickening) of material in a sheet metal forming process, as a percentage of the original sheet thickness.

For example, if this result shows a value of -0.10 this means the material has thinned by 10% of the original sheet thickness at that location.

To see an AVI example of this output, please visit the downloads page.

Calculated forming force for each process:

During each forming simulation process, the forces required to form the metal are being calculated. It is possible to output (for each piece of tooling in each process) the forces experienced and required to form the sheet metal.

This is vital information at the early stage of a sheet metal tooling project, when it is important that the required tonnages are understood, to ensure appropriate production equipment (press machines) are available.

Tonnages outputed from the forming simulation are MINIMUM requirements and some allowance should be added (eg: 20%) to allow for press machine inefficiencies and other mechancial energy losses.

Die face data provided as IGS:

In order to perform a sheet metal forming simulation, die face data is required. This data can be initially provided by the client (in the case of SimulateLite) OR is created as part of the SimulateComplete service.

The client can select to receive the final die face data as used in the simulation, whether it be ADJUSTED die face data (including adjustments or changes needed to countermeasure problems) OR the die face data created by the Engineers at StampingSimulation.com

The die face data can be used in a real tool build, to create the surfaces of the tool exactly as they were simulated. This is the best way to ensure the simulated result can be produced at first tool tryout. The surfaces are provided as 3D IGS CAD data.

Developed blank shape provided as IGS data:

This output should be "required" when the client needs an accurate blank shape development through the forming process. The end result is an IGS file containing the developed blank outline and can be used for first try blank development.

In many cases, the development will be accurate enough to be considered "final" however, it is always recommended that a laser cut or proto cut blank is trialed first from this data. A blanking tool should not be cut directly from this data!

The difference between this result and a one step result, is that the entire forming process is considered, stage by stage. This means if the actual tool build matches the process simulated, this blank development will be very accurate in reality.

Springback analysis and resulting color error map:

This output should be "required" when the client is concerned about springback being a problem after the sheet metal is formed. This output predicts the MAGNITUDE and DIRECTION of springback.

The result is shown as a color error map using a scale showing magnitude, in a JPG format.

Springback compensated die face data as IGS:

Springback is a well known sheet metal problem. Using simulation technology, springback can be predicted to a reasonable degree of accuracy and then compensation can be made. Clients whom have requested "Springback analysis and resulting color error map" can choose to go an extra step, by "requiring" this option and having their die face design compensated for springback.

The end result is a die face design that has allowance for springback already built in.

Formal report of all requested outputs:

Although each simulation job always has an AVI output showing tooling, formability and thinning (when appropriate), the option to have all the results summarized in a formal report is also available.

A formal report is useful when presenting simulation results to your customer when it may not be possible or appropriate to view an AVI file OR when you need to present formally on paper during a tool design meeting.

Reports are issued in XLS or PDF format.