Punching Technology Simulation Shortens Coordination Times in Toolmaking

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At Rosenberger Stanztechnik, Stampack Xpress supports method planning, layout creation, and feasibility inquiries in the field of stamping die technology.

The Rosenberger Group, based in Fridolfing, Germany, specializes in connection solutions, particularly in high-frequency, fiber optic, and high-voltage technology. The company supplies customers in the telecommunications, data technology, medical electronics, industrial measurement technology, automotive electronics, and e-mobility sectors and employs over 15,000 people worldwide. Here, the company plays to its strengths, such as high product quality, technological competence, and a high degree of value creation.

Rosenberger Stanztechnik GmbH & Co. KG is an important addition to the existing stamping part production: The subsidiary focuses on the production of demanding, high-precision contact parts for the automotive, telecommunications, and electronics industries.

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Interface to the CAD System and Customized Handling

Rosenberger Stanztechnik has its own toolmaking facility and design department at its headquarters in Neuenbürg near Pforzheim. Since January 2022, the Stampack Xpress simulation software has been in use in the latter. "During the selection process, Stampack particularly convinced us with its interface to our existing CAD system VISI as well as the handling adapted to toolmaking," emphasizes Stefan Maier, the head of the Technical Competence Center (TCC) of Rosenberger Stanztechnik. "Especially in method planning during layout creation and when assessing feasibility inquiries, Stampack provides us with excellent services. As a result, we were able to reduce coordination times by saving on revision loops."

Stampack Xpress is developed and distributed by Stampack GmbH from Bietigheim (Germany). Since its market launch in 2010, Stampack Xpress has enabled the simulation of progressive dies. With enormous improvements in the computational speed of its own 3D volume solver, Stampack is suitable for both complex forming in the contact connector area and large automotive parts.

Complete Package for Product Developers and Method Planners

New developments such as iterative springback compensation and trim line determination make Stampack Xpress a complete package that is now used by over 150 customers in the development process. The practice-oriented software is equally suitable for product developers and method planners and can be used without prior knowledge and practical experience in FEM.

Stampack calculates an initial estimate with the fast shell solver and then an exact description of the forming process with the volume solver without changing the simulation definition. The calculation of springback and springback compensation is included, as well as a tolerance check that allows manufacturing tolerances to be monitored and deviations displayed graphically in the software. The fast volume solver simulates the processes during the forming of thick sheets and material compressions very realistically and is therefore also suitable for the simulation of progressive die processes.

Stampack fully met the expectations of the specialists at Rosenberger Stanztechnik. With very complex products with step changes, coordination work was often very time-consuming and costly. In these cases, the geometry of the blank had to be determined through several trials, and support in product development or feasibility analysis was required.

Shorter Development, Faster Turnaround Times

"With the help of Stampack, we were able to achieve our set goals such as reducing tool tuning times and thereby achieving faster throughput times. Additionally, we can save resources and manufacturing capacities through fewer recursions and detect blank cracks early in strong forming operations," concludes Stefan Maier positively. "Apart from the short calculation times of the volume solver, we particularly like the software's user-friendliness, which has enabled our designers to represent even complex forming processes on the computer in a very short time. These completely positive experiences with Stampack have led to the software now also being used at the headquarters in Fridolfing at Rosenberger Hochfrequenztechnik GmbH." (st)

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