With our know-how from over 65 years and in close cooperation with you, we develop parts for all types of sheet metal parts. This includes structural parts made of steel, aluminum and stainless steel, as well as visible parts made of steel and aluminum. Tool weights of up to 40 tons and sizes of up to 5000 mm x 2500 mm can be realized. We produce sheet metal parts in these and smaller sizes for follow-on composite tools, transfer tools, road tools and prototype tools.
Tool development for sheet metal parts
For the development and optimization of parts, producibility and costs are decisive factors. That’s why we perform a feasibility study which you are involved in before the project begins. When planning the project, a central focus is not only cost-effective implementation but, above all, a reliable method for a stable series production.
With our part simulation we are able to evaluate processes in sheet metal forming in advance and thus optimize producibility. After performing a feasibility study, we examine parts for cracks, compressions, strains and sheet thinning. The drawing lines are secured at the same time. This reduces subsequent faults in production and costs. For the simulation, we use the software Autoform.
After forming, there is a risk of elastic deformation of parts. To compensate for this, the part is purposely configured incorrectly and the springback is then calculated using the simulation results and experiential values. Springback compensation measures effectively reduce correction loops, cost and time expenditure. We use the software Autoform for these procedures.
In method planning we make an initial decision on which production processes are best suited for the project. Among the different types, we differentiate between stamping, pressing and drawing. Next, we identify the individual operational steps. Feasibility, process capability and the calculated cycle time must be ensured during planning. We use the software Catia V5 for method planning.
We design all tools with great attention to detail, using the method plan, the component simulation and the component data on the computer as a basis. During construction, we focus primarily on production-ready implementation. This is based either on the tender specifications specific to your tools or on the tender specifications for house tools, which is based on OEM standards. Catia V5 software is used here.
Absorption surface construction
The absorption surface is the place on the sheet metal that comes into direct contact with the tool. Be it die, punch, binder or during trimming and post-forming, there are active surfaces for every tool component. In each case, sheet thinning and clearings are directly included in the design. We use the software Tebis for the absorption surface construction.
NC programming is a standardized offline programming on a computer that uses a color system. It allows for paper-free production and simulation and crash monitoring which can be used to recognize and utilize process optimization potential. We use the software Tebis for NC programming.
For CNC processing, we have access to ultra-modern machinery. Our 5-axis milling machines are equipped with the latest milling technology and are used for Highspeed Speed Cutting (HSC), roughing and finishing. We work with a full range of tools of up to 7000 mm on the machines from our manufacturers DMG and Hermle. The machine controllers iTNC530 and TNC640 are used.
Assembly & Tryout
The tools are assembled in benchwork groups and are then installed in tryout presses and tested. In this way, the first parts, samples and small series can already be pressed and the tools can be optimized in parallel. The serial production processes are thus gradually initiated based on trial and error.
The new ILSe – ST 1500/35 represents state-of-the-art high-quality “Made in Germany” machine building. In the system as a whole, it is used as a “swivel cutting tool” and is used to produce a range of blanks, including, in particular, trapezoidal blanks. The comprehensive concept can be used in current standard presses in your company. It is also possible to simply integrate the swivel drive into your systems. The advantages of both applications are maximum performance, economy, long-term accuracy and quality, reliability and security. The technology developed by us offers numerous functions:
- segment drive with ultra-high dynamics and performance, and wear-free operation as there is no contact
- Vibration-damping, robust cast machine construction
- Extremely flat machine design: less than 180 mm
- Contact-free, wear-free hydrostatic bearing in axial and radial direction
- Contact-free and wear-free measurement system with maximum precision
- Recovery of braking energy
- Mobile adjustment panel
ILSe can also be implemented in your company. Find out more in our PDF document or get in touch and we will be happy to provide information in person.