Expected results

Concrete results of the project will be:

a) New products:

1) Method for manufacturing Smart servo sheet metal forming tools

The main result of the project SmartMforming will be developed method for manufacturing Smart servo sheet metal forming tools. With this method the real sheet metal forming tool for the automotive industry will be manufactured and tested in real industry environment. After the end of project we will use the results of this project to offer our customers smart tools as an alternative to conventional cold forming and explain them all advantages of servo systems.

2) CATIA AddOn

Result of the project will be a CATIA AddOn that will be completely integrated into computer-aided design (CAD) software (CATIA). Integration of the AddOn into CATIA software is important due to request for shorter product development time and development cost reduction. The ability of performing kinematics of Sheet Metal Forming Tool CAD Model will have a great impact on product development time and cost reduction. Besides that, by allowing of carrying out virtual kinematic, the result of the development or optimization process of a component will be enhanced. These results will be more accurate and further eliminating mistakes.

3) CNCSTAMP and MES Linkage

Within the project there will be prepared studies of user requirements for the Manufacturing Execution System (MES), analysis of the existing situations and user requirements for data capture, notification, and reporting, micro-planning and potential links with other IT control, supervision and management systems in automotive industry (e.g. ERP, DMS).


b) Demonstrator

Smart tool with sensors and servo systems embedded for automotive industry tested in real industry production:

1) For the demonstrator TPV has given three different sheet metal parts from automotive industry. All of them are going to be investigated in project and for one of them will be developed the smart sheet metal tool which is going to be tested in real environment in the industry.

First sheet metal part from the automotive industry is “Traverse”.

“Traverse” is a sheet metal part made from 2.5 mm thick high-strength sheet material. The part is integrated into the cooling system of truck MAN. TPV produce around 50.000 products per year.

Second part is “airbag holder” which is made of 2 mm thick high-strength sheet material. The part is made in 11 forming and cutting operations. Left and right part (they are symmetrical) are made in the same sheet metal tool. The airbag holder is directly mounted into the “Traverse”. On these two symmetrical parts is mounted airbag for the passenger. In 2015 TPV produced 202.000 products.

The third part is “adapter bracket”. The part is integrated into the car LAND ROVER. The part is mounted to the car body and holds back seats. In 2015 TPV produced 55.000 products. The part is made in the sheet metal tool with 9 different operations. The high-strength sheet material is 5 mm thick.