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How to create a complex formed metal part (connector terminal)

Question asked by Matt Wilhite on Nov 23, 2012
Latest reply on Nov 27, 2012 by Matt Wilhite

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Hi, can anyone help me with this kind of problem?

Attached is a drawing of a connector terminal. The part is a stamped and formed part, manufactured on a progression die. It has a number of transition areas and varying cross-sections.

I want to be able to create this kind of part, but the trick is to generate accurate models for both the fully formed part and the blank part, so that the part can be folded and unfolded accurately using the same 3D model.

Is this really possible with the SolidWorks sheetmetal functionality, or is there some add-on SW partner package that is needed? If the latter is the case, can you recommend the partner product that would be needed?

Thanks for your help!

Matt

Kelvin Lamport Nov 23, 2012 12:47 PM

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You would probably need 3rd party software to flatten that part.

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Kelvin Lamport Nov 23, 2012 12:47 PM
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You would probably need 3rd party software to flatten that part.
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- Matt Wilhite @ Kelvin Lamport on Nov 26, 2012 8:25 AM
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  Hi Kelvin,
  
  Thank you for the links to the third party software (potential) suppliers. This is very helpful to look at all these different options. I spoke with Logopress people in France last Friday because they were recommended by the Solid Solutions people here in Ireland. I am waiting for their response after they received the drawing. But I believe it can be done with Logopress3.
  
  I will contact Amada in Japan also, because that company has supplied us already with excellent formed connector terminals. I did not know they also have a software arm.
  
  Thank you sir.
  
  Matt
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Anna Wood Nov 23, 2012 1:00 PM
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If you do a lot of this type of work you want to look at Logopress or 3DQuickPress for strip development and die design.

If this is a one off, the part can be modeled and the strip developed using SolidWorks sheet metal tools with some tricks to help with the transitions. We use a mix of sheet metal tools and good old fashion manual drafting techniques/2D AutoCAD skills for a part like this when creating a strip layout.

I am assuming you will have the math data from Molex for the terminal.

What CAD system have you been using in the past for progressive die design? I am just curious.

Cheers,

Anna
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- Anna Wood @ Anna Wood on Nov 23, 2012 6:13 PM
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  After reviewing your website I am going to suggest another option for you.
  
  I would not be to worried about using the SolidWorks sheet metal tools to model your connectors. I would suggest you use the tools you use today for your designs. The sheet metal tools in SolidWorks may limit what you want to do trying to conform to its rules. Use the regular SW features, you will also find the surfacing features with a thicken will give realistic sheet metal transitions for the edge treatments as well.
  
  Logopress3,3DQuickPress offer modules for flattening parts and blank development. You an also go higher end with a product called BlankWorks. These I believe would be better suited to your needs.
  
  Cheers,
  
  Anna
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- Matt Wilhite @ Anna Wood on Nov 26, 2012 8:32 AM
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  Hi Anna,
  
  Thank you also (besides Kelvin) for good recommendation. I really want a seamless design transition between product design, blank development and tool design for metal parts, because otherwise it is just too inefficient and problems compound when someone wants a change to either the final product, the blank layout or the forming tooling for any one of a number of reasons. So I agree with you that SW is limiting in this respect.
  
  I never used CAD before for progression die design. In my previous job, we did product design and tooling management, but most of our dies were designed and built externally by a number of die houses, who would use a number of different tools and methods. I never got that close to them to see exactly what they were doing. I was only good at complaining when the parts weren't made right :-)
  
  Thank you for your help and best of luck with your projects.
  
  Regards,
  Matt
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  - Michael Fernando @ Matt Wilhite on Nov 27, 2012 1:47 PM
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    Hi Matt,
    As a LP3 user I’m certain it is a solution for your inquiry, and would like to prove it if possible to get the complete details.
    
    This kind of parts are known to me as in-die assembly process of two prog. parts made together parallelly in the same press. With gratitude to my previous German employer and where I learnt truly precision die designing skills, in 1996 I was involved in designing these modular dies and have seen them running at 600-800PPM with perfect timing and 100% quality inspected with vision systems. (Even today, here in Canada it’s hard to find someone who could believe me and in thistype of process speed 16 years ago.)
    
    I’m not trying to scare you off, but just mentioning the software alone will not be a solution. Since 1996 CAD systems have developed so far and ahead, but make sure you have necessary skilled personal using it otherwise you will not see the ROI and the market competiveness.
    
    Best regards,
    Michael Fernando
    www.solidCADworks.com
    
    Attached is a real strip (not a rendered CAD model)
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    solidCADworks_k-16.jpg460.0 KB
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    - Matt Wilhite @ Michael Fernando on Nov 27, 2012 12:00 PM
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      Thanks Michael.
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How to create a complex formed metal part (connector terminal)

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