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The paper illustrates the application of a tool kit of computer programs to evaluate possible process designs and tooling details for clamshell type heat exchangers. The work demonstrates modelling rules for analyzing local, regional and global features of a complex stamping. Local analysis is performed on each critical area using the plane strain and axisymmetric approximations as well as a three dimensional model of the beads. Global three dimensional models are then used to investigate interactions between main features. The forming forces, flywheel energy and out-of-balance forces required to select the press are evaluated. It is shown that the design and analysis programs within the Tool Kit are complementary to each other; each providing a different information perspective, each satisfying different lead time and accuracy requirements to address design and analysis needs.

The paper describes a methodology, developed for process engineering at the quoting stage, for matching the press requirements with the tooling requirements in the quest for achieving a quality pressing, with low tooling and press maintenance costs. The starting point is the process plan of the part. The approach is based on subdividing the deformation of the part within a station into elemental deformation regions. The load-displacement diagram for each elemental region is calculated individually, and then totalled to estimate the total load-displacement curve for each forming station. The total energy requirements, as well as the change of the load centre during the stroke for each forming station, is then calculated. The procedure also incorporates the effect of change of timing (e.g. staggering of actions). The approach is then extended for the case of multiple dies acting on the same press (e.g. transfer press and progressive tooling).