**1. Introduction**

20 Industrial Design – New Frontiers

Tseng, F., Cheng, A., & Peng, Y. (2009). Assessing market penetration combining

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scenario analysis, Delphi, and the technological substitution model: The case of the OLED TV market, Technological Forecasting & Social Change, Vol.76, 897–

> Sheet metal is commonly used in the automotive industry. The requirements for developing approaches for manufacturing automotive panels have become increasingly important as carmakers seek to shorten their time to market. However, designing and manufacturing mold dies for automotive sheet metal panels is time-consuming as several processes use the trial-and-error method. The die design period for one sheet metal panel is usually a few months to up to one year.

> Along with advances in Computer-Aided Design (CAD), simulation of interference checking can be conducted using a three-dimensional solid model, and Computer-Aided Engineering (CAE) software can be used to simulate and analyze die face to accelerate the design process (Fig. 1).

Fig. 1. Design process of die design

Cold dies are used for drawing, trimming, restriking and piercing when manufacturing sheet metal (Fig. 2).

Fig. 2. Manufacturing process of automobile sheet metal

#### 1. Drawing (DR) mold

Drawing is the first operation in a manufacturing process in which a metal blank is drawn without wrinkles or cracks.

Knowledge-Based Engineering Supporting Die Face Design of Automotive Panels 23

Product-in face is the outside of a sheet metal piece that can be seen after being assembled in

Addendum is the surplus area outside the product-in face that facilitates drawing operations; thus, when designing an addendum, the quality and strength of a sheet metal

Normally when designing a die face, except for such parts as product-in face, the addendum, and binder—the three main parts—other features like drawbead and the stamp mark during the drawing operation, trimming line during the trimming operation, and convex hull during

Fig. 5 shows the design process for a die face. When stamping a piece of sheet metal, no area should be unable to be pressed; that is, undercut (Fig. 6). The upper mold and lower mold should be fully pressed against each other during drawing and all areas that must be drawn should be drawn at one time; therefore, avoiding an undercut is the first priority when

the restriking operation are also included in die face to facilitate those operations.

an automobile and is shaped during drawing and, thus, is included in the die face.

Fig. 3. Features on fender design

Fig. 4. Divisions on die face

**2.2 Designing a die face** 

designing a die face.

piece after drawing must be considered.
