Robust design method and intelligent system for trimming die of complex automotive panel

The design process of automotive trimming die is very complicated, time-consuming, and error-prone process because of the complex geometric shape of the part surfaces and the trimming lines. This paper presents a systematic methodology for intelligent design of automotive trimming die. Template subtraction and bounding volume strategy (TSBV) is presented to unify the design process of blades in pad, punch, and trimming inserts. The novel horizontal and vertical offset algorithms are developed to construct the quality-derived surfaces based on geometric offset mapping (DS-GOM) quickly and stably, which are applied to generate the bounding surfaces of the template solids in TSBV. Finally, a robust and intelligent design system for trimming die of automotive panel is implemented on NX platform in this paper. And the intelligent system is adopted to design the trimming die for the actual and classical automotive panels to verify the effectiveness and stability of the developed system. Compared with traditional method, the generated surfaces by DS-GOM have the smooth transition which can improves the robustness of developed system. Case studies and industrial applications have demonstrated that the system can improve the design efficiency by 74.2% compared with generic design system.