Chassis Structural Part Transfer Die Project
Challenge
The client required an 8-station transfer die for chassis front subframe cross members with annual output exceeding 500,000 pieces. Challenges included: transfer precision control across multiple stations, springback compensation for high-strength steel (DP780), and stringent German client requirements for die life and stability.
Solution
Used FEA to optimize die structure for rigidity and strength. Applied AutoForm for full-process springback simulation and compensation. Key stations equipped with independent micro-adjustment mechanisms achieving ±0.05mm transfer precision. Selected Swedish SSAB premium die steel with PVD coating.
Result
Dies successfully delivered and in mass production at 12 SPM, die life reaching 1.2 million strokes. Part dimensional qualification rate of 99.2%, highly recognized by the German client, awarded as Supplier of the Year.