T-SIM Transfer Simulations, Help Make Manufacturing Decisions

T-SIM Transfer Press Simulation Software is a decision-making tool in addition to its well-known benefit of increasing production by optimizing your existing tooling.

The Shaking Bars Case Study

  • The Customer: A stamper in Michigan
  • The Problem: The customer was experiencing severe bar shake and part control issues when running two specific parts (right side and left side part). As a result, they also experienced a crashed tool causing unnecessary expenses
  • The Press: An older link motion press
  • The Transfer System: Standard Tri-Axis Transfer System with purchased fingers and grippers

The Solutions offered to fix the Shaking Bars before T-SIM Solutions was introduced:

Option 1: Slow Down the Press

CONS: Limiting production would be a loss of revenue. In this instance, they were already at the minimum SPM so this option was invalid

Option 2: Purchase new and stronger transfer bars

CONS: Downtime with press would be a loss of revenue and large capital expense ($150,000+)

Option 3: Upgrade the entire transfer System

CONS: Downtime with press would be a loss of revenue and large capital expense ($350,000+)

Before T-SIM completed a transfer press simulation for this customer, they were very limited in their options and the only feasible options required a large capital expense with money out of pocket.

How Did T-SIM Software Help this Customer?

The customer was referred to an authorized T-SIM provider by a tooling supplier who works directly with T-SIM Solutions for several other stamping customers.

The T-SIM Service Provider collected information for the press specs, transfer system, tool specs/design, and the current press settings.

The data was imported into T-SIM Simulation Software and the initial T-SIM report easily identified the root issue: excessive G-Forces with the clamp in and clamp out motions.

At that point, an Automated Optimization Simulation was performed, during which the T-SIM Provider adjusted the G-Forces to have a lower target force in the problem areas and increased the speed in areas that were running slower than the equipment was capable of.

WITHOUT ANY PHYSICAL CHANGES TO THE TOOL and only changing simple settings the results speak for themselves: 20% faster at 18 SPM with far better part control and the bar shake issue completely resolved.

The T-SIM Provider also noted suggestions in the Corrective Action Report (CAR) that could increase production rates further by making minor alterations to the tooling.

View our before and after videos below and notice the drastically reduced shake within the bars. You do not have to be an experienced T-SIM Provider to get these results in your own facility. Our software is very intuitive and easy to use. If you would like to know more, please contact us today!

Before 15 SPM and after T-SIM 18 SPM. Notice the Bar Shake is gone!

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