Engineeringskills
Development of formed parts in steel, aluminum and stainless steel
From the initial idea to serial production
The development process for sheet metal series parts
In order to produce formed and stamped parts from sheet metal precisely and efficiently, the development process is usually carried out in stages.
During development, it is important to always keep an eye on the manufacturing process. This is where we, Precision Forming (PFS), come into the equation. The earlier we, as tool and forming specialists, are involved, the more certain the feasibility of the manufacturing process. “Extra rounds” or manufacturing “dead ends” are identified at an early stage.
Together with our partner companies EnTech Schuler (development and FE simulation) and Schuler Konstruktionen (forming simulation and tool design), we can accompany you from component development to series production.
The steps to serial production
Component development
Sheet metal forming parts offer many advantages over other manufacturing processes:
High strengths can be achieved, sheet metal forming parts are material-efficient, easily reproducible, and inexpensive to manufacture in large quantities.
Therefore forming parts are popular in the automotive and consumer goods industries.
Component development and design are carried out using 3D CAD programs such as Catia, NX, Creo Parametric, and others.
The use of the finite element method (FEM), e.g., with Ansys, during development enables the early identification and optimization of potential weak points even before the tool is created.
Forming simulation and method planning
If it is clear that the component will be pressed, forming simulation during development is useful. Specialized simulation software such as AutoForm and Simufact are used for this purpose. These tools support the optimization of material utilization, minimize the risk of cracking or wrinkling, and enable efficient process design. As a result, a method plan is created which defines the individual tool stages.
Tool design
The tools are developed and designed based on the simulation results. Depending on the component requirements, progressive, transfer, or fine cutting tools are used.
We develop so-called rolling tools especially for transmission parts (lamella carriers).
Prototype tooling and validation
Tests with pre-production parts enable the integration and functionality of the component to be checked in interaction with other parts. Sample parts are then required for product validation. We can provide support here with prototype tools or 3D printing.
3D metal printing / Kolibri Serial production and process monitoring
Production takes place on presses and systems that ensure consistently high quality.
Sensory monitoring systems continuously measure pressing force, material flow, and tool load.
Quality assurance and continuous improvement
We use optical measurement techniques, non-destructive testing methods, and regular random checks to ensure that all components meet the required specifications. Findings from production are integrated into a continuous improvement process.
This structured development approach ensures that our components are manufactured efficiently and to the highest quality standards.
Good to know
Tolerances and types of tools
Modern presses and pressing processes enable components to be manufactured efficiently in large quantities without compromising on stability, dimensional accuracy, or functionality. A well-thought-out design that takes the requirements of series production into account already in the development phase is crucial for cost-effective manufacturing.
Through close coordination between design, toolmaking, and production, we ensure that your component is technically mature and can be manufactured economically.
We support our customers in particular in the development of formed parts with the highest precision.
You can benefit from our expertise in fine blanking technology or tool manufacturing (roll tools) for rotationally symmetrical parts.
Precision Forming is at home in forming technology and toolmaking.
Fine cutting tools
Fine cutting tools are special punching tools used in the fine cutting process. They are distinguished by the following features:
- Triple action: In addition to the normal cutting punch, there is a ring-shaped tooth holder (holding plate) and a counterholder.
- Minimal burr formation: Since the sheet metal is firmly clamped during the cutting process, smooth, right-angled cut surfaces are produced without any significant burrs.
- High precision: Typical tolerances are in the range of ±0.01 mm to ±0.05 mm.
- Fine blanking tools are more expensive than standard punching tools, but are well worth the investment for components with tight tolerances and high surface quality requirements.
Rolling tools for sheet thicknesses up to 6 mm – tolerances in the range up to 0.15 mm
Sheet thicknesses of up to 6 mm are mainly used in powertrain technology for high forces or torques in automobiles. These components are often rotationally symmetrical—but in any case, they are manufactured with high precision and corresponding tolerances.
This is where our rolling tools are used in conjunction with fine blanking technology. This minimizes tolerances. Only a few toolmakers have mastered this technology. We at Precision Forming are one of them.
Tolerances in the range of a hundreths millimeter
The tolerances that can be achieved for formed parts depend on several factors, including the material, the forming process, and the tool used. The general tolerances for sheet metal parts are usually in the range of ±0.1 mm to ±0.5 mm. However, precision formed parts can also achieve tolerances of ±0.05 mm or better.
The thickness and shape of the component also play an important role. Thinner sheets (<1 mm) can generally be processed more precisely than thick sheets (>3 mm). In the case of complex shapes and geometries, material flow and springback have a greater influence on tolerance accuracy.
An overview of the tolerances for different types of tools:
“Normal” punching and cutting tools, bending tools, deep-drawing tools The usual tolerances in toolmaking vary between ±0.1 mm and ±0.5 mm. For pure punching and cutting tools, the range is ±0.1 mm to ±0.3 mm; for deep-drawn parts, the springback of the material must also be taken into account.
The tolerances then increase to ±0.2 mm to ±0.5 mm. If tighter tolerances are required, fine-cutting tools are the right choice.
Metal forming
Progressive dies with tolerances in the hundredths range are our strength.
With our patented fine-cutting pads, we can achieve tolerances on conventional presses that are otherwise only possible on fine-cutting presses.
This is complemented by our expertise in the field of roll tools for sheet metal up to 6 mm thick.
Surface and heat treatment
We “purify” products for the automotive, aircraft, and bicycle industries.
Our series parts production has facilities
- for heat treatment of aluminum (hardening and aging) as well as
- for finishing your parts by means of brushing, vibratory grinding, and polishing
Serial production
The production of precision sheet metal parts made of steel, stainless steel, or high-strength aircraft aluminum, as well as complete assemblies, is our second mainstay.
Our customers value our expertise in forming technology, heat treatment, parts finishing, and assembly.