t3 summit - · pdf filebody-in-white closures, exhaust systems, and manufacturing equipment...
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Body-in-White Closures, Exhaust Systems, and Manufacturing Equipment
HIROTEC AMERICA3000 High Meadow Circle
Auburn Hills, MI 48326
248-836-5100
www.hirotecamerica.com
T3 Summit
Presented April 24, 2017
Page 2
Main Products
7 Million Doors 1.8 Million Exhausts
Assembly Systems
Hemming
Systems
Stamping
Dies
Page 3
HIROTEC Closure DNAFull Vertical Approach
Page 4
Tool & DieStamping Dies
Designer and manufacturer of high quality stamping dies
−Class A surface quality with best fit and finish conditions
−Over 80 years of production know-how
Page 5
HIROTEC Approach
Hand
worked die
bearing
Panel
quality
Typical US Industry Approach
Panel
quality
HIROTEC Bearing
(Hand Work) Philosophy
Hand
worked die
bearing
Page 6
HIROTEC DNAFull Vertical Approach
Manual
Bearing
Adjustment
Functional
T/O
Single
Panel
Adjust
Review
Single
Panel
Adjust
Review
Single
Panel
Adjust
Assem
Adjust
Assem
Review
Single
Panel Die
Mods
Assem
Adjust
Assem
Review
Single
Panel Die
Mods
Vehicle
Match
Bear-ing
Adj.
Functional
T/O
Single
Panel
Adjust
Review
Single
Panel
Adjust
Assem
Adjust
Assem
Review
Single
Panel Die
Mods
Assem
Adjust
Assem
Review
Single
Panel Die
Mods
Vehicle
Match
Typical US Industry Approach
Extensive manual bearing adjustment time with focus on gate milestones
Single panel dimensional QI focus with single panel quality gate milestone approval
Shift to assembly QI after single panel milestone gates are met
Final step minor match to body just before SOP if required
Typical HIROTEC Approach
Manual bearing adjustment is considered non value add. Trust machining accuracy and remove hard spots
Single panel dimensional QI focus for major dimensional and formability issues
Quickly move into assembly QI and target assembly dimensional quality milestone
Final step minor match to body just before SOP if required
Page 7
Part Coordination Fixture (PCF)
Duplicate of all GEO net pads and clamps
Allows for individual part inspection (except for outer panel)−HIROTEC philosophy is no checking fixture for the outer panel
Allows for assembly of inner sub
Page 8
Surface Distortion Compensation
Strain Analysis
“Analysis” Estimation
Data Insert
Surface distortion is evaluated in simulation
Compensation is added based on historical data
Compensation is confirmed in simulation
This process results in a significant reduction in highly skilled hand work during the tryout process
Page 9
Laser Surface Buildup Welding
Manual surfacing welding
−Highly dependent on operator skill
−Difficult to accurately control thickness
−Longer machining times
−High heat input
• Potential for cracking & warping
Laser surfacing welding advantages
−Predictable buildup dimensions
−Low risk of voids and additional repair
−Low heat input
• Shorter machining time
• No cracking or warping
−Reduced cycle times
−Elimination of operator weld skill requirement
Page 10
Laser Surface Buildup Die Example
Laser cladding
−Example of 15mm die surface buildup
Laser hardening of stamping dies
− In addition, the laser system can also be used for CNC surface hardening
• Very accurate, consistent hardening
• Reduced heat input
• Reduction in highly skilled labor
Page 11
CAE Activity for Flex Prediction & Compensation
ADVENTURE Cluster (SCSK)
Page 12
Hammer Peening Surface Treatment
Hammer Peening Advantages
−Reduction in surface machining time
−Elimination of most surface hand work
−More consistent friction coefficient match with material flow simulation resulting in better virtual world to real world match
−Side benefit of improved surface hardness during die tryout stage
−The above results in a significant reduction of high skilled labor input
−And shorter tryout times improving speed to market