ADVANCED CAM TURNS TO ESI GROUP'S STAMPING SIMULATION SOFTWARE FOR FASTER DESIGN OF AUTOMOTIVE PARTS

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ADVANCED CAM TURNS TO ESI GROUP'S STAMPING SIMULATION SOFTWARE FOR FASTER DESIGN OF AUTOMOTIVE PARTS
12 October 2005 - ESI Group

For Advanced Cam, a die production designer for automotive components, meeting requirements for part quality, piece cost and delivery lead time demands an in-depth understanding of the stamping process.

Advanced Cam relies on PAM-STAMP 2G simulations to provide customers with "right first time" tool designs for automotive components in order to run production with a minimum of manufacturing risks. This cost-efficient sheet metal stamping simulation tool, developed by ESI GROUP (ISIN FR0004110310), covers the entire tooling process from quotation and die design through formability and try-out validation. PAM-STAMP 2G includes modules PAM-DIEMAKER for rapid die creation, PAM-QUIKSTAMP for rapid stamping evaluation and PAM-AUTOSTAMP for forming process validation, quality and tolerance control.

The latest progress in the software is the possibility to accurately predict springback, allowing effective die compensation to correct this effect. Using PAM-STAMP 2G, Advanced Cam modifies the tooling geometry at an early stage of the design phase in order to compensate for the effect of springback.

"The accuracy of the simulation from PAM-STAMP 2G, and the precision of the graphical results make it the foundation of my business. We have upgraded to PAM-STAMP 2G since January 2004 after 5 years of using the previous version, and found that, among other benefits, it runs much faster than the previous version. For example, a simulation that once took 10 hours to process now only takes half the time. Springback calculations run in minutes instead of hours. This enables us to modify tool design and achieve high quality die tooling of automotive components," said Eric Wilhelm, Owner, Advanced Cam Inc., Utica, MI.

"Springback is a major problem in production, particularly with High Strength Steel as the part shape after springback may not be within tolerance and could be unsuitable for the intended application. The amount of springback depends upon the distribution of stresses at the end of the forming, which in turn results from the properties of the material and the geometry of the part." added Dave Ling, Stamping Product Manager ESI Group. "Using PAM-STAMP 2G, Advanced Cam modifies the tooling geometry to compensate for the effect of springback."

With PAM-STAMP 2G Advanced Cam has been able to reduce the design cycle whilst increasing component quality and accurately predicting wrinkles, splits and springback. Through the use of simulation, manufacturing risks have been minimized, engineering changes and downstream problems have been reduced and processing time is cut back with the MPP (Massively Parallel Processing) version.

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About: ESI Group
ESI Group is the world leading software editor for the numerical simulation of prototype and manufacturing process engineering in applied mechanics. The key to ESI Group's success is the use of realistic material physics, providing "as good as real" virtual solutions, in order to replace the lengthy trial and error processes on real prototypes.

ESI Group has developed an entire suite of coherent industry-oriented applications to realistically simulate a product's behavior during testing, to fine tune the manufacturing processes in synergy with the desired product performance, and to evaluate the environment's impact on product usage. ESI Group's product portfolio, which has been industrially validated and combined in multi-trade value chains, represents a unique collaborative, virtual engineering solution, known as the Virtual Try-Out Space (VTOS), enabling a continuous improvement on the virtual prototype.

By drastically reducing costs and development lead times, VTOS solutions offer major competitive advantages by progressively eliminating the need for physical prototypes.

A sustained growth

Total consolidated revenue for fiscal year 2003, ending January 31st 2004, increased by 15% in real terms and 22% at constant exchange rates, compared to the previous year reaching 49 million euro.

The software activity remained stable with 73% from licenses and 27% from services.

The major acquisitions made in 2002 and 2003 accounted for 15% of revenue growth and took part in the strengthening of the Group's position on the American market.

As in previous years, ESI Group maintained a strong international presence with 50% of turnover generated outside Europe and 79% of revenue outside.

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ESI Group also provides high value-added services, worldwide through its subsidiaries located in Europe, Asia and Americas. Consulting projects with strategic industrial partners as well as European R&D contracts exemplify ESI Group's strong engineering knowledge and scientific expertise.

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