by Hari Purwanto

Automotive Business Review

Global Automotive Market

Motor Vehicle Producing Countries 2011

China
United States
Japan
Germany
South Korea
India
Brasil
Mexico
Spain
France
Canada
Russia
Iran
Thailand
UK
Czech. Rep.
Turkey
Indonesia
Poland
Argentina
Italy

18,418,876
8,653,560
8,398,654
6,311,318
4,657,094
3,936,448
3,406,150
2,680,037
2,353,682
2,294,889
2,134,893
1,988,036
1,648,505
1,478,460
1,463,999
1,199,834
1,189,131
837,948
837,132
828,771
790,348
0

5,000,000

10,000,000

15,000,000

20,000,000
Data from Wikipedia

Automotive Business Review

Global Automotive Market

Vehicle OEM by Volume

9,000,000
8,000,000
7,000,000
6,000,000
5,000,000
4,000,000
3,000,000
2,000,000
1,000,000
0
Toyota

GM

Volkswagen

Hyundai
Motor

Ford

Nissan

Honda

PSA

Suzuki

Renault

Data from Wikipedia

Automotive Business Review

Indonesias Car Sales in 2011

893.420
Data Kompas.com

Automotive Business Review

Indonesia Automotive Market

Automotive Market in Indonesia ( in Thousand Units)

1200
1000
1000

893
765

800
Amount

607
600

400

500

483

422

387

200
59

301

300

318

2000

2001

2002

411

355

296

94

0
1997

1998

1999

2003

2004

2005

Year

2006

2007

2008

2009

2010

2011

2012

Data from Gaikindo

Automotive Business Review

Opportunity of Indonesias Automotive Business :

Big Population
People Carrier
Growth of Agriculture, Mining and Forestry Business
Trucking
Growth of Infrastructure
Transporter
Government Regulation (Low Cost Car & Green Car)
Additional Investment by OEM

Automotive Business Review

Challenging of Indonesias Automotive Business :

Global Product

CBU imported from Thailand, China, US, etc (Sedan, Pick-up, MPV, SUV and Truck)

Global Supplier or Tier-1 of OEM present at Indonesia

Trustworthy , Keiretsu (Japan Business Culture)

Quality
Global Quality Requirements (ISO/TS 16949) and Engineering Competency for
Domestic Investment (Local Company)

Cost
Competitive Cost and Engineering Competency for Domestic Investment (Local
Company)

Environment Requirements
Green Product and Process (ISO 14001 and Customer Requirements)

Car Components

ELECTRIC

DRIVE SYSTEM

BODY

UNDER BODY COMP

(CHASSIS COMP.)
ENGINE

POWER TRAIN

Body and Chassis

Body and chassis made of steel sheet
Widely used metal forming technology

Body of passenger car

Frame Chassis of SUV / Pick Up

Frame Chassis of Truck

Metal Forming Technology

What is Metal Forming ?

WHY, HOW does

metal forming technology ?

Mass Production
Cold Process
Steel Sheet/Strip

Metal Forming Technology

DIES / MOULD

SHEET METAL

PRESS MACHINE

PRODUCT

Metal Forming Technology

Forming group :

Metal Forming Concept

Type of bending and forming are V bending, L/U bending and curved bending

Neutral Plane

(b) Shape of cross section a b c d

(C)

(d) V- and U- bending ( Spring back and spring go condition)

Metal Forming Concept

Force for V Bending

Pbv = (k1 x Fs x w x t )/(1000 x L)

2

Where :

Pbv = Force for V-bend (tf)

Fs = Material Tensile strength (kgf/mm2)
w = Bending length (mm2)
t = Sheet thickness (mm)
L = Span of V die (mm)
k1 = coefficient (1.0 ~ 1.5)

Metal Forming Concept

Force for U Bending

Pbu = (k2 x Fb x t x w)/1000

Where :

Pbu = U bending Force (tf)

t = Sheet thickness (mm)
k2 = Coefficient (0.22 ~ 0.4)
Fb = Sheet tensile strenth (kgf/mm2)
w = bending length (mm)

Cushion and pad forces for U Bending

The pad force should be about one-fourth to one-third of U Bending.

Pbu = Pbu + Pbp

Where : Pbu = requisite bending force
Pbu = bending force
Pbp = Cushion and Pad force (1/3 ~ 1/4 Pb)

Metal Cutting Concept

Cutting Group

Metal Cutting Concept

Metal Cutting Concept

Clearance between punch and die

Clearance between punch and die edge designed 5 ~ 10 % of thickness material (one side).

Blank edge sheared with insufficient

clearance and material undergoing shear
with insufficient clearance

Blank edge sheared with excessive

clearance and material undergoing shear
with excessive clearance

Metal Cutting Concept

Blanking Force
Pp = ( A x Ps ) / 1000
Where : Pp = Blanking Force (tf)
A = Shear area (mm2)
Ps = shear resistance of workpiece
(kgf/mm2)
fp = penetration factor (fp = h/t)
c = clearance between punch and
the side of die ( c = (dd dp) / 2)

Metal Cutting Concept

Stripping Force

Ps = ( 2.5 x l x t ) / 1000
Where :

Ps = Stripping Force (tf)

l = blanking circumference (mm2)
t = thickness (mm2)

Stripper is component that make fix position of work piece

during blanking process. This force is generally 2.5 ~ 20 %
of the blanking force (commonly 5 ~ 8 % is used)

DIES TECHNOLOGY

PROCESS DESIGN
TOOLING DESIGN
MANUFACTURING

ASSEMBLING OF DIES
PRODUCTION
MAINTENANCE

DIES TECHNOLOGY
PROCESS DESIGN

Requirements :
- Part Drawing
- Productivity

- Maintenance Die
- Press Machine

DIES TECHNOLOGY

Part Drawing
Customers use part drawing for ordering
Dimension and other specification that state clearly on part drawing must
be used reference for design process of dies
Productivity
Unit/hour of part for stamping process called is Stroke Per Hour (SPH). It
depend on press machine and handling of part during production.
Automation or manually handling of part must be considered for die
design
1 die = 1 process Single type
1 die = 2 processes or more with feeding continue of material
progressive type or compound type
1 die = 2 processes or more without feeding continue of material gang
type
Maintenance Die
Dies must be maintained during production time. Dies maintenance are
preventive and repair.
Press Machine
Press capacity, press type (hydraulic and mechanical) must be considered
for design process of dies.

DIES TECHNOLOGY

Design Process Drawing of Dies

Material Selection : SKD, SKS, etc.
Design Point :
- Cutting Process
Clearance between punch & die No burr
Contour of punch/die
Reduce cutting Force
Strip Layout
- Forming Process
Clearance between punch & die Spring Back/go
Radius of Die Bending
Reduce bending force

DIES TECHNOLOGY
TOOLING DESIGN

Steps to Design Die :

1. The Scrap Trip
The firs step in designing any die is to lay out the material strip exactly as it will appear at the
bottom of the press stroke.

or

DIES TECHNOLOGY
TOOLING DESIGN
2. The Die Blocks
Die blanking or bending placed in steel that called is die blocks.
Die Blocks

3. The Blanking Punch or Bending Punch

DIES TECHNOLOGY
4. Pilots

5. Gages or Stopper

DIES TECHNOLOGY
6. Stripper for blanking
Pad / blank holder for bending

7. Fastener

DIES TECHNOLOGY
8. The Die Set

9. Dimensions and Notes

10. Bill of Material

DIES TECHNOLOGY
DIES MANUFACTURING

Material base / holder : FC 30 or SS 400

Machining of Die Components
Heat Treatment/Hardening for Punch / Die is full Hardening
SKD 11 after Full Hardening Hardness = 60 + 5 HRc
Heat Treatment for die/punch blanking : Full hardening, Flame hardening and Induction hardening.
Grinding of Die Material after hardening process
Coating process for die bending after hardening process. Various of coating for die bending : Toyota
Diffusion (TD), Chrome Plating, Toyo TiC Coating

DIES TECHNOLOGY
DIES ASSEMBLING
Dies use pilot & dowel pin for mistake proofing for
assembling each component after tightening by bolt.

Various fastener

DIES TECHNOLOGY
PRODUCTION
Productivity Stroke per Hour (SPH)
Machine & Process (Loading/Unloading)
Die Facilities :
Ejector
Pin ejector
Air ejector
Scrap Cutter
Shooter of part
Automation
Air Cylinder (Automation pusher)

DIES TECHNOLOGY
MAINTENANCE

Lifetime of Tools to Maintain

Man Power Skills Method to maintain (knowledge of tools, product & process)
Die history must be recorded in Tag Die. All about problem of dies and action for repair
or preventive maintenance must be recorded clearly.
Tools for Maintenance :
Grinding, Sanding, Welding, Wrench, Oil Stone, machining, etc.

Study Case : Dies for Rear Axle Part of Light Duty Truck

REAR AXLE ASSY

HOUSING
REAR AXLE

HINO DUTRO /
TOYOTA DYNA
TRUCK

HOUSING
UPPER & LOWER ASSY
UPPER / LOWER

IMPROVEMENT
PROCESS

BREAKDOWN STAMPING
PARTS

Study Case : Dies for Rear Axle Part of Light Duty Truck

START
FINISH
RECEIVING /
8 X 260 X 1300

FORMING /
MECHANICAL PRESS 1000 T
BLANKING /
PLASMA CUTTING ROBOT

RESTRIKE

TRIMMING /
PLASMA CUTTING ROBOT

START
FINISH
RECEIVING /
8 X 218 X 1245

BLANKING /
MECHANICAL PRESS 1000T

FORMING /
MECHANICAL PRESS 1000 T

RESTRIKE 1 /
MECHANICAL PRESS 1000 T

RESTRIKE 2 /
MECHANICAL PRESS 1000T

Study Case : Dies for Rear Axle Part of Light Duty Truck

Blank layout estimation

Simulation software 3D Quickform

1. 3D Modelling

6. Drafting by software

2. Surfacing (1/2 thick of material)

5. Solid blank

3. Meshing

4. Line blanking

Study Case : Dies for Rear Axle Part of Light Duty Truck

Failure Analysis

Thinning Simulation (Unit mm).

Simulation of the failure analysis to see changes in the thickness of the addition and
subtraction on the product. If the thickness reduction of> 20% thicker product, it is not safe in
the sense necessary to the addition step forming.

Thinning max :
= 20% x thick material.
= 20 % x 8 mm
= 1.6 mm
Conclusion :
= Actual : limit
= 0.8149 mm < 1.6 mm

OK

Study Case : Dies for Rear Axle Part of Light Duty Truck

Failure Analysis
Equivalent Stress ( Unit Mpa )
Failure analysis to see the magnitude of the stress that received material. The material terms
should not exceed the ultimate tensile stress of the 2 X product properties.
Example : Housing material is SPH490HY-SB which has ultimate tensile stress: 567 MP

Equivalent stress max :

= 2 x ultimate tensile stress
= 2 x 567 Mpa
= 1134 Mpa
Conclusion :
= Actual : limit
= 424.4 Mpa < 1134 Mpa

OK

Study Case : Dies for Rear Axle Part of Light Duty Truck

Analisa kegagalan process forming

Efective plastic strain
Failure analysis to test the limits of accepted plastic material (elongation).
The material terms should not exceed% elongation of the material product.
Example : Housing material is SPH490HY-SB which has elongation 33%.

Effective plastic strain max :

= 33%

Conclusion :
= Actual : limit
= 16.37% < 33%

OK

Study Case : Dies for Rear Axle Part of Light Duty Truck

Cost and Benefit Analysis

NO

SPECIFICATION

EXISTING PROCESS

DEVELOPMENT PROCESS

PROFIT

Process Cost / pcs

Rp. 78.325

Rp. 36.560

Rp. 41.765

Consumable tooling cost /

pcs

Rp. 31.898

Rp. 6.600

Rp. 25.298

Total benefit / pcs

Average production process /

month

Total profit process cost /

month

Rp. 67.063
1200 pcs / 600 unit

1200 pcs / 600 unit

Rp.80.475.600

Tooling investment

Rp. 880.000.000
depreciation 5th
Tooling cost/month
Rp. 14.666.667

Benefit / month

Rp. 80.457.600 Rp
14.666.667

Pay back period

880.000.000 / 65.808.933
13.4 month

Rp. 65.808.933