A designed experiment (DOE) was performed on a specific sheet metal part in a stamping plant. The independent variables were material thickness, shut height inner, shut height outer, press speed, lubricant concentration, and film build. The dependent variables were outer tonnage, 15 dimensional points and 10 formability points. An in-process gage was used to measure draw and finish panels. High correlations for the models were achieved by following a detailed methodology and by utilizing a successful measurement system analysis.; The key variables and their operating zones were determined. A standardized process set-up reduced variation. The standardized process set-up compromised between the dimensional issues and the formability issues of wrinkles and splits.; The two most important process parameters were the material thickness and shut height outer. The key interactions were (a) material thickness and shut height outer, (b) lube concentration and film build, and (c) shut height outer and part dimension.
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