Abstract
The quality of sheet metal panels in BIW depends on the quality of the die development. Core panel stamping dies range from 2m to 4m, designed with multiple varying sections and includes number of casting elements of various lengths. These stamping dies are subjected to cyclic impact forces and can develop cracks at weaker sections during its operation. Hence, it is essential to ensure recommended casting Rib thickness to avoid die damage. In conventional way, casting thickness is checked and validated by passing section along model in multiple directions and accuracy of the modeling verified by the random measurement. This process is tedious, adds to human errors and time consuming. The primary objective of this study is to develop an automated process to evaluate and to ensure recommended casting rib thicknesses and also to validate the accuracy of modeling designed in 5mm multiple as it is a requirement in die design. The methodology is developed by studying existing method with the objective to find out alternative methods to overcome the disadvantages. In order to overcome the drawback of manual checking, visual rib thickness utility was developed by customizing the CAD environment. The tools developed is added to standard utility without any additional cost. This utility ensures casting strength and integrity of automotive stamping dies by ensuring Rib thickness as per standard guidelines at various sections.