NX 6 - Progressive Die Design through Manufacture

Process Optimization

Aaron Frankel
Senior Marketing Manager

Image courtesy of Verbom Inc.

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Key Business Issues
- for mold and die tool manufacture

Global competition
How to:

Compete on price
Products are more

Shorten delivery times complex, no margin

Win on complex jobs in simple jobs

Meet quality demands
Today’s consumers
expect high quality

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NX Progressive Die Design Process Overview

Structure Design Detailing

Process Design Design Validation

Blank &
Most complete and fastest Electrode Design
Intermediate Stages
process from design to
manufacture through
intelligent automation & Wire EDM

Part Analysis
process integration

Hole Making &

Machining

Import to NX
(STEP,IGES,… Production
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 Part Preparation
Part Preparation “Being able to unform complex shapes at the various stages is a huge advantage that
Part Analysis separates NX from its competitors. Most parts are produced in multiple stages. If you
Flattening /
can predict what they look like in those perform stages, you are better able to make
Unforming the end product look like what the customer wants.”
Mike Molina II, President, Progressive Design Technologies
Process Design
Initialize Project
Hybrid Model
Blank Layout
Design Change Propagation and Control

Straight Break + Freeform Part Analysis Flattened Blank

Scrap Design
Engineering Process Management

Strip Layout
Straight Straight
Structure Design Break Break
Die Base

Inserts

Standard Parts

Detailing
Relief
Pocketing
Intermediate Stages
BOM
Drawings

Validation

Manufacturing

Electrodes
Freeform Straight
CAM Break
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 Formability Analysis
Part Preparation “One-step Unforming, a fast and accurate sheet metal unforming solution, can help
Part Analysis to reduce and even eliminate effort / time on costly physical try-outs.”
Flattening /
Rainer Lahme, Software-Consultant CAx, EDM, Chief Information Office, Wincor
Unforming Nixdorf
Process Design
Thickness Analysis Results
Initialize Project Enhanced
Blank Layout
with NX 6
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design Thinnest

Die Base Areas
Inserts

Standard Parts

Detailing
Relief
Pocketing
BOM
Drawings

Validation
Stress, Strain, and Springback Analyses
Manufacturing

Electrodes
CAM
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 Blank & Intermediate Stage Preparation
(straight break regions)
Part Preparation “Progressive Die Design provides new capabilties to create intermediate
Part Analysis stages for straight break sheetmetal parts based on unparameterized bodies
Flattening /
-- fast and easy!“
Unforming Christine Ramsteiner, Application Engineer, BCT Technology AG
Process Design
Initialize Project
Enhanced
Blank Layout with NX 6
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design
Multi-step
pre-bends
Die Base

Inserts

Standard Parts
Unbend

Detailing
Relief
Pocketing
Overbend
BOM
Drawings

Validation
Associative
Manufacturing Intermediate
Stages
Electrodes
CAM
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 Blank & Intermediate Stage Preparation
(freeform regions)
“One-step Unforming, a fast and accurate sheet metal unforming solution, can help
Part Preparation
to reduce and even eliminate effort / time on costly physical try-outs.”
Part Analysis Rainer Lahme, Software-Consultant CAx, EDM, Chief Information Office,
Flattening / Wincor Nixdorf
Unforming

Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base Intermediate Stage Mesh Flattened Wireframe Profile

Inserts

Standard Parts

Detailing
Relief
Pocketing
BOM
Drawings

Validation

Manufacturing

Electrodes Result: Flattened Blank

CAM
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 Process Design
Part Preparation
Quickly obtain an accurate strip layout for cost estimation and quoting.
Part Analysis Design the design structure based on the fully detailed strip.
Flattening /
Unforming

Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design Blank Layout

Die Base

Inserts

Standard Parts

Detailing
Relief Project Initialization
Pocketing
BOM
Drawings Scrap Design

Validation

Manufacturing

Electrodes
CAM
Strip Layout
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 Project Creation
Part Preparation Project Initialization creates a standard data structure for managing the various
Part Analysis relationships between parts and processes of the die design. Define the part material
Flattening /
upfront in the design cycle to automate down-stream design calculations such as
Unforming bending properties and force calculations.
Process Design Standard Progressive Die Project Structure Configurable Project Templates
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts

Detailing
Relief
Enhanced with NX 6
Pocketing
BOM
Drawings

Validation

Manufacturing

Electrodes
Material Database
CAM
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 Blank Layout - Nesting
Part Preparation Blank Layout provides all of the necessary parameters to specify how
Part Analysis the part(s) is nested within the strip. Multiple and different parts can be
Flattening /
inserted into the layout.
Unforming

Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base
Blank Layout
2-up
Inserts
nesting
Standard Parts Real-time
update of
Detailing
material
Relief utilization
Pocketing
BOM
Drawings
Rotation
Validation

Manufacturing

Electrodes
CAM
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 Scrap Design
Part Preparation “NX Scrap Design can be used to effectively design scrap with round radii even
Part Analysis when the part or blank has sharp corners, this is an important capability to
Flattening /
improve our design quality.”
Unforming Christian Kloz, Dipl.Ing (FH), Steudle-Kontakte GmbH
Process Design Sketch Profile
Initialize Project Enhanced
Blank Layout with NX 6
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts

Detailing
Relief
Pocketing
BOM
Drawings Overlap/Overcut
Validation

Manufacturing

Electrodes
Scrap Design
CAM
Piercing Pilot
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 Strip Design and Validation
Part Preparation “We can generate a nice strip and have a precise estimation of material usage.
Part Analysis Our costing and quoting is far more accurate, and we can give customers detailed
Flattening /
information that we couldn’t provide in the past.”
Unforming Andrew Niewiara, Engineering Manager, Wiegel Tool Works
Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout Strip Layout

Pierce Form Bend
Structure Design

Die Base

Inserts
Enhanced
Standard Parts
with NX 6
Detailing
Relief Association strip
Pocketing simulation
BOM
Drawings Drag & drop
Validation between stations

Manufacturing

Electrodes
CAM
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 Structure Design
Part Preparation
Quickly design the complete die structure using a comprehensive and configurable
Part Analysis library of die bases, insert groups, and standard parts.
Flattening /
Unforming

Process Design
Initialize Project Die Base Die Module Standard Parts Bending Punch & Die
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts

Detailing
Relief
Pocketing
BOM
Drawings

Validation

Manufacturing

Electrodes
Strip Layout Piercing Punch & Die Forming Punch & Die
CAM
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 Die Base Design
Part Preparation Load the die base and easily adjust its defining parameters.
Part Analysis Control plate configurations, lengths, heights, and gaps.
Flattening /
Split the sub-die base into multiple modules.
Unforming

Process Design Split Die Base Enhanced with NX 6

Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts

Detailing
Relief Die Base

Pocketing
BOM
Drawings

Validation

Manufacturing

Electrodes
CAM
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 Piercing Insert Design
Part Preparation
The combination of piercing punch and die with slug hole can be quickly designed
Part Analysis using the Piercing Insert Design command. Fine Blanking procedures are
Flattening / supported by defining variable offset parameters.
Unforming

Process Design Foolproof

Initialize Project
corner
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts Slug Hole Non-planar hole

punch automation
Detailing
Piercing Punch & Die
Relief
Pocketing Enhanced
Cavity
BOM
Hole with NX 6
Drawings
Fine-blanking
Validation

Manufacturing

Electrodes
CAM
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 Insert Group Design
Part Preparation “NX further accelerates the process with pre-defined parameters for
Part Analysis spring back compensation available within forming punch and die catalog parts.”
Flattening /
Michael Volk, Application Engineer, alphacam
Unforming

Process Design Enhanced with NX 6 Insert

Initialize Project Group
Blank Layout Library
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts
Z and V Bends 90 Bend
Detailing Z Bend
Relief Punch
Pocketing & Die
BOM
Drawings

Validation

Manufacturing
Pocketing Forming Punch & Die
Electrodes
Geometry
CAM
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 Standard Parts
Part Preparation
“With NX Progressive Die Design, we are capturing and reusing our design and
Part Analysis process knowledge to streamline our tool design through production processes.”
Flattening / Jos Schaetti, President, Schaetti
Unforming

Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts

Detailing
Relief
Pocketing
BOM
Drawings

Validation

Manufacturing
Standard Parts
Electrodes
CAM
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 Detailing
Part Preparation Quickly and effectively add the finishing design details to the die structure.
Part Analysis Document the entire design with efficient BOM and drawing
Flattening /
creation / automation tools.
Unforming

Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design
Die Structure Details
Die Base

Inserts

Standard Parts

Detailing
Relief
Pocketing Drawings
BOM
Drawings

Validation

Manufacturing

Electrodes
CAM BOM Hole Table
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 Relief Design
Part Preparation
The Relief Design feature enables quick design of associative reliefs.
Part Analysis Relief bodies can be instanced to downstream stations.
Flattening /
Unforming

Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts

Detailing
Relief
Pocketing
BOM
Drawings

Validation
Relief for Forming Feature
Manufacturing

Electrodes
CAM Relief
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 Pocketing
Part Preparation
Inserts and standard parts are designed to contain “False Bodies” for automation
Part Analysis of pocket cutouts for die plates. A “False Body” is a solid body hole representation
Flattening / used to cutout the plate pocket. Multiple cutouts can be quickly performed
Unforming
in the same operation.
Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts Pocket Design

Detailing
Relief
Pocketing
BOM
Drawings

Validation

Manufacturing

Electrodes
CAM
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 BOM
Part Preparation The BOM function is flexible and is used to create various formats of the BOM –
Part Analysis export the BOM to excel, html, or drawing parts list. The BOM can be easily edited
Flattening /
and configured to report pre-defined attributes on parts such as material, supplier,
Unforming description, etc.
Process Design
Initialize Project
Enhanced with NX 6
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design BOM Export to Excel

Die Base

Inserts

Standard Parts
BOM Export to Browser
Detailing
Relief
Pocketing
BOM
Drawings

Validation

Manufacturing

Electrodes
Stock
CAM
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 Drawings - Documentation
Part Preparation
Document the design by quickly creating assembly and components drawings.
Part Analysis Use NX Drafting to add views and annotation.
Flattening /
Unforming

Process Design
Initialize Project BOM
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts

Detailing
Component Drawing
Relief
Assembly Drawing
Pocketing
BOM
Drawings

Validation

Manufacturing

Electrodes
CAM
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 Drawings - Documentation
Part Preparation “The Hole Table function performs quickly and is useful for automating
documentation processes.”
Part Analysis
Randy Moodie, NC Programmer, Minco Tool and Mold, Inc.
Flattening /
Unforming
Ordinate Dimensioning Hole
Process Design Table
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design Enhanced

Die Base with NX 6
Inserts

Standard Parts Top Plate Drawing

Hole ID
Detailing
Relief New
Pocketing with
BOM
NX 6
Drawings

Validation Wire EDM Start Hole Reporting

Manufacturing

Electrodes
Hole Table
CAM
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 Design Validation
Part Preparation
“NX Progressive Die Design includes a powerful Tool Design Validation capability
Part Analysis that streamlines the clearance and interference checking process.”
Flattening / Michael Hoffmann, Application Engineer, alphacam
Unforming

Process Design
Initialize Project
Enhanced
Blank Layout
Design Change Propagation and Control

Scrap Design with NX 6

Engineering Process Management

Strip Layout
Interference Check
Structure Design

Die Base

Inserts

Standard Parts

Detailing
Relief
Pocketing Force Calculation

BOM
Drawings

Validation

Manufacturing Enhanced
Electrodes with NX 6
CAM
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 Manufacturing
Part Preparation
Streamline manufacturing by leveraging the broad capabilities of NX CAM.
Part Analysis Automate manufacturing processes by leveraging attributes pre-defined on
Flattening / plates and components.
Unforming

Process Design Automated Hole-making WireEDM High Speed Machining

Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts

Detailing
Relief
Pocketing
BOM
Drawings

Validation

Manufacturing

Electrodes
Electrode Design Machining Simulation Machine Tool Simulation
CAM
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 Electrode Design
Part Preparation “The NX Electrode Design product provides the breadth of integrated tools necessary
Part Analysis for the electrode design process.”
Flattening / Takahiro Maruyama, Chief Tool Design and Manufacturing Engineer,
Unforming Shonan Design Co., Ltd
Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts Die Block Electrode Burn Area

Standard Parts

Detailing Enhanced with NX 6

Relief
Pocketing
BOM
Drawings

Validation
Electrode Validation Electrode Drawing

Manufacturing

Electrodes
CAM
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 NX CAM Integration
Automated Hole-making

Part Preparation ”With the advantages of NX Progressive Die Design and NX CAM we essentially doubled
Part Analysis our design capacity by halving design lead time. We also increased machining capacity
Flattening / by 15% on 15 machines. All of this sums up to increased profitability.”
Unforming Yvon Laplante, President, Verbom, Inc.
Process Design
Product Manufacturing Information
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts
Pocketing  Die Plate Machining Features Generated Tool Paths
Standard Parts

Detailing
Relief
Pocketing
BOM
Drawings

Validation

Manufacturing

Electrodes
CAM Tool Path Verification
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 NX CAM Integration
WireEDM

Part Preparation ”With the advantages of NX Progressive Die Design and NX CAM we essentially doubled
Part Analysis our design capacity by halving design lead time. We also increased machining capacity
Flattening / by 15% on 15 machines. All of this sums up to increased profitability.”
Unforming Yvon Laplante, President, Verbom, Inc.
Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts

Detailing
Relief
Pocketing
BOM Define WireEDM Geometry & Attributes Generate Tool Path
Drawings

Validation

Manufacturing

Electrodes
CAM
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 Shop Floor
Part Preparation “The manufacturing information we generate with NX makes it very clear for the
Part Analysis people on the shop floor exactly which processes to use. This information is
Flattening /
contained in the design data from the beginning.”
Unforming Yvon Laplante, President, Verbom Inc.
Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base
Shop Docs Shop Floor Visualization
Inserts

Standard Parts

Detailing
Relief
Pocketing
BOM
Drawings

Validation
Resource Management Quality / Inspection
Manufacturing

Electrodes
CAM
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 Design Change & Propagation Control

Part Preparation “We are dealing with design changes everyday… if we change an angle or move a
Part Analysis bend line or a hole on the strip layout, everything else on the die is
Flattening /
automatically updated, even the tool paths. Everything is linked in NX.”
Unforming Yvon Laplante, President, Verbom Inc.
Process Design
Local Change to Part  Update Strip  Update Insert  Update Drawing & CAM
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts Strip Pitch Change  Update Scrap  Update Strip  Update Piercing Insert  Update CAM

Standard Parts

Detailing
Enhanced
Relief
Pocketing
with NX 6
BOM
Drawings
Local Change to Part  Update Scrap Boundary  Update Strip  Update Piercing Insert  Update CAM
Validation

Manufacturing

Electrodes
CAM
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 Engineering Process Management

Part Preparation Engineering Process Management provides the framework to manage project data
Part Analysis and revisions, synchronize relationships between design and manufacturing data,
Flattening / and implement workflows to achieve consistent and streamlined
Unforming design through manufacturing processes.
Process Design
Initialize Project
Blank Layout
Design Change Propagation and Control

Scrap Design
Engineering Process Management

Strip Layout

Structure Design

Die Base

Inserts

Standard Parts

Detailing
Relief
Pocketing
BOM Project Data & Process Management Manufacturing Data &Process Management
Drawings

Validation

Manufacturing

Electrodes
CAM
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Thank you.

© 2007. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software