Defining the operating window for an automotive sheet pressing operation

A methodology was developed that allowed the operating window of an automotive sheet metal forming process to be defined. The method was applied to a production panel drawn on a 1200 t double action press in an automotive stamping plant. The effects of corner pressure, shut height and draw speed on quality were examined using a full factorial design of experiment (DoE) and a series of empirical models were consequently developed. These models were expressed visually to allow production personnel to understand how the methodology permits a more robust combination of press variables to be selected.