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V O L U M E 21 – N O . 8
OCTOBER 2019

Simulation at
Volvo Cars Industry 4.0 in focus
Coil processing
Automation and robotics
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THE GLOBAL SHEET METAL FORMING AND FABRICATION JOURNAL
FACE TO FACE FACE TO FACE

PARTNERS IN PROGRESS
transfer presses. A lot gained market share but quality and safety are
of dies are analysed to still the over-riding principles of our operation
support all the new car here," he continued.
models in production.
From 2000, with TriboForm modelling
major changes in its Mats is working on a new friction modelling
workload and multiple project using AutoForm's TriboForm software,
Simulated sheet metal forming operations have improved product projects on hand, it made which has changed his perspective on how
TriboForm: software
quality, reduced body component lead time and married a more to simulate friction the decision to to look at simulation results. Two things have
distinct, attractive design with improved manufacturability at and lubrication just use AutoForm software a huge impact on results – one is material
conditions for sheet metal forming. The properties and the other is tribology. Friction,
Volvo Cars Body Components’ plant in Olofström, Sweden. entire AutoForm solution has he says, is 'a can of worms'. TriboForm is
allowed Volvo Cars Body Components to software for the simulation of friction and
perform more accurate simulations, analyse lubrication conditions. Through a more realistic
more parameters and ensure many more consideration of tribological effects, a new level
“We visited Volvo’s plant at Olofström, 150km loops and robustness evaluations. of simulation accuracy can be achieved.
north east of Malmö, which produces more than "We need to be innovative and find "The quality of sheet metal formed parts
fifty million car body components per year using answers to new challenges. We also is strongly dependent upon the tribology and
AutoForm sheet metal simulation software.” parts. Expertise in the shaping and joining of need to be nimble and able to adapt to friction conditions that act during the forming
steel body panels has grown immensely strong different challenges," Mats Sigvant, process. These friction conditions are then
in Olofström over many years and is the key Technical Expert, Forming Simulation, Volvo dependent upon the tribology system i.e. the
to its success. It has developed a strong and Cars told ISMR. Mats works in the advanced applied sheet material, coating and tooling
stable partnership with AutoForm Engineering engineering department, working closely with material, the lubrication and process conditions,"
GmbH on sheet metal simulation software, the CAE department and advising on aspects explained Mats Sigvant.
using several AutoForm modules to simulate of friction testing, simulation and sheet metal Marc Lambriks, General Manager, AutoForm
sheet metal forming and stamping processes, material properties. Engineering Netherlands, explained why this
in its factories worldwide. "We are also carrying our simultaneous is important.
Volvo Cars' stamping CAE department, which engineering for Volvo Cars parts for Asian "Current trends are geared towards
numbers ten people (dedicated to simulation and U.S. suppliers, not just Volvo factories lightweighting and they bring challenges.
and related activities), is the nerve centre for in Sweden, and manufacturing dies for The use of thinner but stronger materials is
stamping and stamping-related issues at Volvo Volvo Cars press lines in China. The part challenging for general formability. However,
Cars. Volvo Cars Manufacturing Engineering must be feasible to produce in any Volvo forming thinner sheet materials is also more
Left to right: Johan Nedemo, Manager, Die Process Engineering Tool&Die;
Mats Sigvant, Technical Expert, Forming Simulation, Manufacturing Engineering, Stamping at Olofström has, with the smart factory in the world. That’s a big change for dependent upon friction and tribology for the
Volvo Car Body Components plant at Olofström in Sweden Strategy&Concept, and Kristoffer Trana, Technical Expert, Stamping Feasibility at Volvo Car Group use of metal forming simulation techniques, us in terms of ways of working, as well as final quality of the part. Therefore, what we
improved the manufacturability of Volvo Cars' being very challenging, but it has worked are seeing is a movement where tribology
distinctive design and reduced costs and part quite well. It is a new way of thinking – it's and friction is becoming more relevant for

T
he first Volvo car rolled off the ISMR was invited to visit its plant at Olofström is a high-tech manufacturer of body panels for all lead-times. about readiness for production anywhere accurately simulating the forming of those
Gothenburg production line in Sweden to meet Volvo Cars' sheet metal experts on Volvo's car models and also delivers to external Volvo Cars Manufacturing Engineering and forward thinking. Last year, we passed parts," he told ISMR.
in 1927. Since then, Volvo Car Group forming, testing and simulation. The production customers such as Volvo Trucks. uses AutoForm CAE software for draw-die 600,000 cars and our 2020 target is 800,000 "The goal of utilising TriboForm in Volvo
has been a byword for safety technology of body components has been located in development/optimisation, layout of trimming cars. Our sales have increased and we have car projects is twofold. First of all, the aim
and innovation. In 2010, Volvo Cars was Olofström (Sweden) since 1927 but the high- An eye on sheet metal and flanging tools, detection of surface defects,
acquired by Zhejiang Geely Holding (Geely tech factory celebrated its 275th jubilee in 2010 At Olofström, the operation focuses solely on prediction and compensation of springback,
Holding). Today, Volvo Cars is one of the (it started in 1735 as a blacksmith's mill). With core business – panel pressing, engineering, optimisation of material usage etc. Pre- The quality of sheet metal formed parts is
most well-known car brands in the world around 2500 employees, the Olofström factory die manufacturing and sub-assembly of body production work includes die development,
strongly dependent upon the tribology and friction
selling 642,253 cars in 2018, the company's simulated forming, analysis and the manufacture
fifth consecutive year of record sales. The of die sets for large and medium-sized tandem/ conditions that act during the forming process
largest market, China, represented some
20 per cent of total sales volume in 2018,
followed by the United States (15%), Preparing for the stamping process Production of the Volvo S60L
Sweden (10%), the United Kingdom (8%)
and Germany (7%).
Volvo Cars produces premium-segment
car models in three versions: sedans
(S60, S90), versatile estates (V60, V90)
and SUV vehicles (XC40, XC60, XC90).
Sheet metal forming simulation
software, from AutoForm Engineering
GmbH, has been instrumental in stamping
and forming processes at its 291,314m2
plant at Olofström (Sweden), 150km
north east of Malmö, which produces The XC90 has been made stronger by a more extensive use of hot-formed boron
more than fifty million car body components steel, which is the strongest type of steel presently used in the car body industry.
The amount of hot-formed steel is around 40 per cent of the total body weight.
per year.

18 | sheetmetalplus.com | ISMR October 2019 ISMR October 2019 | sheetmetalplus.com | 19

FACE TO FACE FACE TO FACE

PARTNERS IN PROGRESS
transfer presses. A lot gained market share but quality and safety are
of dies are analysed to still the over-riding principles of our operation
support all the new car here," he continued.
models in production.
From 2000, with TriboForm modelling
major changes in its Mats is working on a new friction modelling
workload and multiple project using AutoForm's TriboForm software,
Simulated sheet metal forming operations have improved product projects on hand, it made which has changed his perspective on how
TriboForm: software
quality, reduced body component lead time and married a more to simulate friction the decision to to look at simulation results. Two things have
distinct, attractive design with improved manufacturability at and lubrication just use AutoForm software a huge impact on results – one is material
conditions for sheet metal forming. The properties and the other is tribology. Friction,
Volvo Cars Body Components’ plant in Olofström, Sweden. entire AutoForm solution has he says, is 'a can of worms'. TriboForm is
allowed Volvo Cars Body Components to software for the simulation of friction and
perform more accurate simulations, analyse lubrication conditions. Through a more realistic
more parameters and ensure many more consideration of tribological effects, a new level
“We visited Volvo’s plant at Olofström, 150km loops and robustness evaluations. of simulation accuracy can be achieved.
north east of Malmö, which produces more than "We need to be innovative and find "The quality of sheet metal formed parts
fifty million car body components per year using answers to new challenges. We also is strongly dependent upon the tribology and
AutoForm sheet metal simulation software.” parts. Expertise in the shaping and joining of need to be nimble and able to adapt to friction conditions that act during the forming
steel body panels has grown immensely strong different challenges," Mats Sigvant, process. These friction conditions are then
in Olofström over many years and is the key Technical Expert, Forming Simulation, Volvo dependent upon the tribology system i.e. the
to its success. It has developed a strong and Cars told ISMR. Mats works in the advanced applied sheet material, coating and tooling
stable partnership with AutoForm Engineering engineering department, working closely with material, the lubrication and process conditions,"
GmbH on sheet metal simulation software, the CAE department and advising on aspects explained Mats Sigvant.
using several AutoForm modules to simulate of friction testing, simulation and sheet metal Marc Lambriks, General Manager, AutoForm
sheet metal forming and stamping processes, material properties. Engineering Netherlands, explained why this
in its factories worldwide. "We are also carrying our simultaneous is important.
Volvo Cars' stamping CAE department, which engineering for Volvo Cars parts for Asian "Current trends are geared towards
numbers ten people (dedicated to simulation and U.S. suppliers, not just Volvo factories lightweighting and they bring challenges.
and related activities), is the nerve centre for in Sweden, and manufacturing dies for The use of thinner but stronger materials is
stamping and stamping-related issues at Volvo Volvo Cars press lines in China. The part challenging for general formability. However,
Cars. Volvo Cars Manufacturing Engineering must be feasible to produce in any Volvo forming thinner sheet materials is also more
Left to right: Johan Nedemo, Manager, Die Process Engineering Tool&Die;
Mats Sigvant, Technical Expert, Forming Simulation, Manufacturing Engineering, Stamping at Olofström has, with the smart factory in the world. That’s a big change for dependent upon friction and tribology for the
Volvo Car Body Components plant at Olofström in Sweden Strategy&Concept, and Kristoffer Trana, Technical Expert, Stamping Feasibility at Volvo Car Group use of metal forming simulation techniques, us in terms of ways of working, as well as final quality of the part. Therefore, what we
improved the manufacturability of Volvo Cars' being very challenging, but it has worked are seeing is a movement where tribology
distinctive design and reduced costs and part quite well. It is a new way of thinking – it's and friction is becoming more relevant for

T
he first Volvo car rolled off the ISMR was invited to visit its plant at Olofström is a high-tech manufacturer of body panels for all lead-times. about readiness for production anywhere accurately simulating the forming of those
Gothenburg production line in Sweden to meet Volvo Cars' sheet metal experts on Volvo's car models and also delivers to external Volvo Cars Manufacturing Engineering and forward thinking. Last year, we passed parts," he told ISMR.
in 1927. Since then, Volvo Car Group forming, testing and simulation. The production customers such as Volvo Trucks. uses AutoForm CAE software for draw-die 600,000 cars and our 2020 target is 800,000 "The goal of utilising TriboForm in Volvo
has been a byword for safety technology of body components has been located in development/optimisation, layout of trimming cars. Our sales have increased and we have car projects is twofold. First of all, the aim
and innovation. In 2010, Volvo Cars was Olofström (Sweden) since 1927 but the high- An eye on sheet metal and flanging tools, detection of surface defects,
acquired by Zhejiang Geely Holding (Geely tech factory celebrated its 275th jubilee in 2010 At Olofström, the operation focuses solely on prediction and compensation of springback,
Holding). Today, Volvo Cars is one of the (it started in 1735 as a blacksmith's mill). With core business – panel pressing, engineering, optimisation of material usage etc. Pre- The quality of sheet metal formed parts is
most well-known car brands in the world around 2500 employees, the Olofström factory die manufacturing and sub-assembly of body production work includes die development,
strongly dependent upon the tribology and friction
selling 642,253 cars in 2018, the company's simulated forming, analysis and the manufacture
fifth consecutive year of record sales. The of die sets for large and medium-sized tandem/ conditions that act during the forming process
largest market, China, represented some
20 per cent of total sales volume in 2018,
followed by the United States (15%), Preparing for the stamping process Production of the Volvo S60L
Sweden (10%), the United Kingdom (8%)
and Germany (7%).
Volvo Cars produces premium-segment
car models in three versions: sedans
(S60, S90), versatile estates (V60, V90)
and SUV vehicles (XC40, XC60, XC90).
Sheet metal forming simulation
software, from AutoForm Engineering
GmbH, has been instrumental in stamping
and forming processes at its 291,314m2
plant at Olofström (Sweden), 150km
north east of Malmö, which produces The XC90 has been made stronger by a more extensive use of hot-formed boron
more than fifty million car body components steel, which is the strongest type of steel presently used in the car body industry.
The amount of hot-formed steel is around 40 per cent of the total body weight.
per year.

18 | sheetmetalplus.com | ISMR October 2019 ISMR October 2019 | sheetmetalplus.com | 19

FACE TO FACE FACE TO FACE
Marc Lambriks, General Manager, AutoForm Engineering Netherlands Die face design is a key part of that process options for NC preparation enable the user to develop future versions of the software," added
and Volvo has built up considerable expertise in modify the designed CAD surfaces for milling Marc Lambriks.
this area over the years. Both options were applied in the forthcoming "The most powerful thing about AutoForm
"From a die face design perspective, we Volvo Cars BEV model. software is that it takes away much of the
consider formability and how to design a part, pain of the classical finite elements and lets
and define the stamping process, to obtain Streamlining workflow you work with the creative stuff to think how
a low level of springback. Do we need to Volvo has been an AutoForm customer for 22 to manufacture the part and determine the
make changes in the process for fewer cracks years. It currently uses AutoForm software process (and not worry about how to do the
and wrinkles, or to get the best geometrical for the engineering of manufacturable sheet- simulation). This is quite important," explained
outcome? Sometimes, we need help from metal parts; estimation of tooling costs early Kristoffer Trana.
part design to facilitate this. We often do part in the planning and bidding phase; simulation- "We work on stamping simulation for
compensations with the AutoForm software to based process engineering; springback every Volvo model across the range,
check if the part is feasible for compensation compensation; rapid creation of high-quality regardless of where it is produced. We also
(rather than for cracks or wrinkles). So many CAD surfaces; simulation of hot forming and do the manufacturing engineering process
Kristoffer Trana (left) and Mats Sigvant
parts are difficult to produce today, so this is quenching processes as well as to ensure for every model, including the newly released
key. It is crucial to choose the right process at robust manufacturing. Volvo is also working Polestar electric model. We make dies for
Below: Overlaid bonnet simulation on the new Volvo XC40 an early stage. Car body electrification is now a extensively on progressive dies and, over selected parts in almost every car model.
Below: AutoForm simulation
consideration; it sets new requirements for the the last two or three years, has worked a lot We also do dies/SE for all models
of the bonnet for the It is important for us to be
Volvo XC40 floor architecture (including battery enclosures) with AutoForm's TriboForm software (virtual (manufacturing engineering processes +
able to help Volvo streamline its and poses new stamping challenges," added tribology modelling to better predict friction in simulation = simultaneous engineering or
overall workflow – AutoForm Kristoffer Trana. the die). SE). Safety is fundamental to Volvo – it is our
software helps it to do that Volvo collaborates continuously with AutoForm "It is important for us to be able to help Volvo number one consideration and is in our DNA."
and provides strong feedback to the software streamline its overall workflow – our software
specialist, running development projects helps it to do that. We have a very strong Coping with
together such as a recent one using AutoForm- partnership with Volvo. As a software company, complexity
ProcessDesigner for CATIA (a CATIA workbench). we benefit from all the input we get e.g. "Generally, very often what is beneficial
"We see Volvo as a strategic partner and we regarding the modelling options in our software, for formability (cracks and splits) can be
learn from each other. The ProcessDesigner the daily usage in a productive environment and counter-productive for springback. You have
for CATIA project sprang from Volvo's desire to the accuracy of our solution. We benefit from to find a balance. Our advanced engineering
bridge the gap between simulation and CAD. the testing that Volvo does and we appreciate departments have considered higher
We recently added the option to compensate for this type of interaction and feedback on our formability materials. You may need to use a
the CAD surfaces (also a Volvo request) and to software. As a partnership is always two ways, different process. We have improved over the
prepare the CAD models for NC machining. The Volvo benefits from our collaboration through years but demands on us have also tightened.
software has been adapted to Volvo's needs active participation in projects and involvement We have reached a point now where we
and we have managed to work Volvo's way and in developments. Such collaboration helps us to should continue with the simulation but
match Volvo's approach to projects which, in
is to apply the the end, provides a real benefit for all our users,"
TriboForm models added Marc Lambriks of AutoForm. Volvo is one of the most advanced automotive
on dies in early die The compensation option enables the user to
users of simulation and has a deep understanding
engineering The motivation effectively use springback simulation results to
is that the majority of the forming compensate the forming tools accordingly. The of the technology behind it
simulations are performed to secure the
die tryout i.e. solve as many problems as
possible in forming simulations before the final Sheet metal simulation
design of the die and milling of the casting. A strong partnership
Secondly, the aim is to study the effects on "Early on, when the first part surfaces are being
stamping results of new lubricants and sheet designed, is where we start. It is a long period
metal coatings." of simultaneous engineering work. This is
Volvo's CAE team benefits from toolroom basically done for all outer skin parts, hang-on
and production facilities that are close to its parts and (sooner or later) for small body in loops. If we purchase dies, we transfer our
operations. Software results need to be tested white (BIW) parts. It starts with 'do we have a simulation (as it is our production intent) and
and tryout is central to develop a large statistical split-free process or wrinkle-free process?" Early the supplier carries on refining and updating
pool of data. on, we want an accurate simulation reading and the contents which are finally signed-off by us
"The problem with friction depends upon accurate process because we want to establish to enable the start of die manufacturing. If we
the surface of the sheet, the coating on the feasibility. We ask ourselves whether this manufacture the dies in-house, we just continue
sheet, the amount of oil, the status of the die, part can be manufactured and which process our work but on an even more refined level.
the speed of the press, temperature etc. So, will suit," Kristoffer Trana, Technical Expert, "Tryout gives you the correct feedback
you can have one result in the toolroom and Stamping Feasibility, Volvo Cars, explained. and you continuously develop your skills and
another on the line. We need to make the die "We worked with AutoForm software from knowledge. We may need to correct and
work in trials and production, so it’s also about the earliest development phase. Later, we improve the simulation. We can sometimes
robustness. On the steel side, we have used decide whether to manufacture the dies in- work with a part (e.g. a fender) for two years
DP800 (dual phase) grades for a long time (our house or purchase them. Part geometry and (from the earliest SE work to final simulation
mainstay for the cold formed, high-strength springback are important issues to get the most during die manufacturing) if we produce the
steels)," added Mats Sigvant. out of the die without too many correction dies in-house."

20 | sheetmetalplus.com | ISMR October 2019

FACE TO FACE FACE TO FACE
Marc Lambriks, General Manager, AutoForm Engineering Netherlands Die face design is a key part of that process options for NC preparation enable the user to develop future versions of the software," added
and Volvo has built up considerable expertise in modify the designed CAD surfaces for milling Marc Lambriks.
this area over the years. Both options were applied in the forthcoming "The most powerful thing about AutoForm
"From a die face design perspective, we Volvo Cars BEV model. software is that it takes away much of the
consider formability and how to design a part, pain of the classical finite elements and lets
and define the stamping process, to obtain Streamlining workflow you work with the creative stuff to think how
a low level of springback. Do we need to Volvo has been an AutoForm customer for 22 to manufacture the part and determine the
make changes in the process for fewer cracks years. It currently uses AutoForm software process (and not worry about how to do the
and wrinkles, or to get the best geometrical for the engineering of manufacturable sheet- simulation). This is quite important," explained
outcome? Sometimes, we need help from metal parts; estimation of tooling costs early Kristoffer Trana.
part design to facilitate this. We often do part in the planning and bidding phase; simulation- "We work on stamping simulation for
compensations with the AutoForm software to based process engineering; springback every Volvo model across the range,
check if the part is feasible for compensation compensation; rapid creation of high-quality regardless of where it is produced. We also
(rather than for cracks or wrinkles). So many CAD surfaces; simulation of hot forming and do the manufacturing engineering process
Kristoffer Trana (left) and Mats Sigvant
parts are difficult to produce today, so this is quenching processes as well as to ensure for every model, including the newly released
key. It is crucial to choose the right process at robust manufacturing. Volvo is also working Polestar electric model. We make dies for
Below: Overlaid bonnet simulation on the new Volvo XC40 an early stage. Car body electrification is now a extensively on progressive dies and, over selected parts in almost every car model.
Below: AutoForm simulation
consideration; it sets new requirements for the the last two or three years, has worked a lot We also do dies/SE for all models
of the bonnet for the It is important for us to be
Volvo XC40 floor architecture (including battery enclosures) with AutoForm's TriboForm software (virtual (manufacturing engineering processes +
able to help Volvo streamline its and poses new stamping challenges," added tribology modelling to better predict friction in simulation = simultaneous engineering or
overall workflow – AutoForm Kristoffer Trana. the die). SE). Safety is fundamental to Volvo – it is our
software helps it to do that Volvo collaborates continuously with AutoForm "It is important for us to be able to help Volvo number one consideration and is in our DNA."
and provides strong feedback to the software streamline its overall workflow – our software
specialist, running development projects helps it to do that. We have a very strong Coping with
together such as a recent one using AutoForm- partnership with Volvo. As a software company, complexity
ProcessDesigner for CATIA (a CATIA workbench). we benefit from all the input we get e.g. "Generally, very often what is beneficial
"We see Volvo as a strategic partner and we regarding the modelling options in our software, for formability (cracks and splits) can be
learn from each other. The ProcessDesigner the daily usage in a productive environment and counter-productive for springback. You have
for CATIA project sprang from Volvo's desire to the accuracy of our solution. We benefit from to find a balance. Our advanced engineering
bridge the gap between simulation and CAD. the testing that Volvo does and we appreciate departments have considered higher
We recently added the option to compensate for this type of interaction and feedback on our formability materials. You may need to use a
the CAD surfaces (also a Volvo request) and to software. As a partnership is always two ways, different process. We have improved over the
prepare the CAD models for NC machining. The Volvo benefits from our collaboration through years but demands on us have also tightened.
software has been adapted to Volvo's needs active participation in projects and involvement We have reached a point now where we
and we have managed to work Volvo's way and in developments. Such collaboration helps us to should continue with the simulation but
match Volvo's approach to projects which, in
is to apply the the end, provides a real benefit for all our users,"
TriboForm models added Marc Lambriks of AutoForm. Volvo is one of the most advanced automotive
on dies in early die The compensation option enables the user to
users of simulation and has a deep understanding
engineering The motivation effectively use springback simulation results to
is that the majority of the forming compensate the forming tools accordingly. The of the technology behind it
simulations are performed to secure the
die tryout i.e. solve as many problems as
possible in forming simulations before the final Sheet metal simulation
design of the die and milling of the casting. A strong partnership
Secondly, the aim is to study the effects on "Early on, when the first part surfaces are being
stamping results of new lubricants and sheet designed, is where we start. It is a long period
metal coatings." of simultaneous engineering work. This is
Volvo's CAE team benefits from toolroom basically done for all outer skin parts, hang-on
and production facilities that are close to its parts and (sooner or later) for small body in loops. If we purchase dies, we transfer our
operations. Software results need to be tested white (BIW) parts. It starts with 'do we have a simulation (as it is our production intent) and
and tryout is central to develop a large statistical split-free process or wrinkle-free process?" Early the supplier carries on refining and updating
pool of data. on, we want an accurate simulation reading and the contents which are finally signed-off by us
"The problem with friction depends upon accurate process because we want to establish to enable the start of die manufacturing. If we
the surface of the sheet, the coating on the feasibility. We ask ourselves whether this manufacture the dies in-house, we just continue
sheet, the amount of oil, the status of the die, part can be manufactured and which process our work but on an even more refined level.
the speed of the press, temperature etc. So, will suit," Kristoffer Trana, Technical Expert, "Tryout gives you the correct feedback
you can have one result in the toolroom and Stamping Feasibility, Volvo Cars, explained. and you continuously develop your skills and
another on the line. We need to make the die "We worked with AutoForm software from knowledge. We may need to correct and
work in trials and production, so it’s also about the earliest development phase. Later, we improve the simulation. We can sometimes
robustness. On the steel side, we have used decide whether to manufacture the dies in- work with a part (e.g. a fender) for two years
DP800 (dual phase) grades for a long time (our house or purchase them. Part geometry and (from the earliest SE work to final simulation
mainstay for the cold formed, high-strength springback are important issues to get the most during die manufacturing) if we produce the
steels)," added Mats Sigvant. out of the die without too many correction dies in-house."

20 | sheetmetalplus.com | ISMR October 2019

FACE TO FACE
Fender for V60

Our productivity figures

are competitive, and
that is largely thanks
to the simulation

Below: Overlaid simulation of fender on new Volvo V60

you have to look at the overall process of it comes to Industry 4.0 and digital twin "Just a year ago, we were CAD modelling
developing the car. It needs to be tightened applications for the future. progressive dies. Now, we use AutoForm
up. You cannot have late changes or late "The structural behaviour of the press and DieDesigner ProgDie software for the die
decisions on suppliers or processes. We need die can also influence the simulation result, modelling. We can make quick decisions and
the right input to get an accurate output. A especially to make milling data compensations be flexible," he continued.
late material grade change can cause massive in time. We have many different cases Volvo is currently working on electrification
problems. The process is complex – changes where failure evaluation methods need to and self-driving (AD) cars. Electrification has
can produce unexpected results so you must be improved. We need to decrease the time had a significant impact on part design. Hybrid
have a reliable model to be able to accurately spent on making die sets etc. It takes too long platforms/architecture are also a challenge. Volvo
predict what will happen," Mats Sigvant to simulate/model the complete process, on has also been inventive when joining aluminium
pointed out. the CAD side, and more needs to be done, to steel, press hardened or mixed metal parts.
Safety and lightweight materials sometimes faster. AutoForm-DieDesigner helps us to do "We are trying to shorten the total time
exhibit slightly peculiar behaviour that needs this in certain applications for simultaneous it takes to develop a car and produce it. So,
to be understood. Volvo is one of the most engineering work. This saves us a huge we are also introducing more things into the
advanced automotive users of simulation and amount of time (probably 50% or more of simulation to detect more problems and shorten
has a deep understanding of the technology time) for geometry creation. The exception is the manufacturing time of the die and ensure
behind it. It also applies it for academic for press hardening dies, where we mostly that the process is robust. It’s about coping with
research. This is particularly important when need to do the CAD," added Kristoffer Trana. complexity," explained Mats Sigvant.

22 | sheetmetalplus.com | ISMR October 2019

FACE TO FACE FACE TO FACE
"For simulation compensations, our target
is within +/- 0.5mm correct from the nominal,
The ultimate aim is to have almost no spotting in
which is quite hard. If there is a mismatch
tryout, giving a result with a dimensionally between part and simulation (maybe 1mm
accurate part. off), we need to investigate which corrections
need to be done in the simulation. Small
adjustments can make a big difference.
Accuracy is everything. Die manufacturing
structural parts) which help us to learn about "The greatest challenge is to shorten the lead simulations must be accurate or everything
high-strength steel forming in-house. This is an times and deliver dies on time for the tryout and is affected. This calls for a high level of skill
important project for simulation development. we work with Kristoffer’s CAE department to and experience. A delay on one project can
You need to have the right die materials, as do the theoretical work on compensations and seriously affect the next die manufacturing
there is a lot of wear, so we use steel block milling data. We want to avoid hard geometry project," concluded Kristoffer Trana.
materials in the dies," explained Johan Nedemo, loops and the milling data must be done to
Manager, Die Process Engineering Team. ensure as short a lead time as possible for the Into the future
"It has been a great learning experience for manual grinding in the dies. So, we need to mill Volvo Cars has announced new financial and
us (we processed almost 1000 steel blocks the dies in the best possible way, with contact operational ambitions designed to position
needed to increase our efficiency). We have in the right places, and reduce manual grinding the company as a leading player in the global
also invested in three new NC milling machines so that the contact between the die and the automotive business by the middle of the
over the last three years, as well as a very large blank are in the correct position." next decade. On the operational side, it
milling machine for the larger dies." The ultimate aim is to have almost no spotting expects to generate half of all sales annually
There is constant demand for new dies, in tryout, giving a result with a dimensionally from fully electric cars, one third of all cars
Stampings at Volvo Cars
as production press lines have grown bigger. accurate part. This is what Volvo aims to sold to be autonomous driving cars and half
From a cost perspective, Volvo aims to do, learning from project to project through of all cars it offers to customers from its
produce as many parts as possible from the simulation and more. subscription service.
same die and the same set-up. "Four or five years ago, we used to do It expects these initiatives to transform its
"As a die manufacturer, we have to adapt compensations (mainly on the draw die). Now, connection to its customer base, with the aim
to that and invest more in bigger presses for we try to do individual compensations in all the of building a total of over five million direct
tryout, larger milling machines and bigger dies to ensure that the part lays stable on the consumer relationships by the middle of the
overhead cranes for lifting. We are in the lower die all the time, otherwise we will deform next decade, creating new sources of recurring
Dies are loaded into the press
middle of this investment period. When you the part when we close the dies and lose control revenue. This will also offer the company far
have big 5m dies like this, it is not a stable of the part quality," added Johan Nedemo greater potential to develop connected and
An eye on accuracy environment. The die half weighs 20 tons Today, Volvo Cars carries out a mixture of other services for customers.
"Geometrical accuracy of the part is a challenge but it still flexes, so we needed to change simulation but also physical scanning of the “Our customers’ expectations are changing
and it needs to be successful every time. We the shop floor and insert flat steel bars to part from the previous die. In the future, it aims rapidly. This means that Volvo Cars is also
have reduced the number of quality loops on support the dies, which can rest on the floor, to use mainly simulation, with not much part changing rapidly. These initiatives will help
the dies, as a result. Simulation helps us to so that there are no trim gaps and the cam scanning. It uses scanning now to evaluate transform Volvo from being purely a car
bring it down, but we need to bring it down adjustments are accurate etc. At the moment, if the simulation is correct - the best time to company to being a direct consumer services
further (repeating this exercise in the toolroom). we are digging a press pit for a new press do that is when it manufactures the dies and provider,” said Hakan Samuelsson, President
We cannot make dies for specific press lines or that we have ordered. Our plan is to make it looks the same as in the simulation. It is and Chief Executive, Volvo Cars.
presses – you never know where the part will further modifications over the next three or important to carry out the simulation and die On the financial side, Volvo Cars aims to
be produced – so robustness in the design is four years. It is a real challenge to adapt to manufacturing activities side-by-side as they generate premium level profitability in line with
key," underlined Kristoffer Trana. the die sizes,” continued Johan Nedemo. complement each other. other premium car makers, driven by increased
Although Volvo has streamlined product Die making at Volvo Cars sales and revenues across all three global sales
and process designs, elements in the process regions, and a broader range of cars including
have changed such as tolerances and stronger processes. Stamping engineering is an iterative adjustments to the die. Some car models share sales to the new segment of autonomous ride-
materials (like aluminium). Industry 4.0 will process – you change the process, you change some parts. hailing companies. The company’s improved
place even higher demands on accuracy. the part. Every part is unique. Part price is also "The moulds for small and large structural financial performance will also be driven
"In terms of Industry 4.0, as a simulation important, as is investment – much depends parts are made here and delivered to Volvo car increasingly in the future by industrial synergies
company we aim to completely digitalise the upon the volume. We are involved very early plants across the world. We produce a wide generated with its affiliated partner companies.
metal forming process chain. With the release in the car development process – stamping is range of parts from draw dies (the smallest Volvo Cars expects to benefit from lower
of AutoForm-TryoutAssistant, we try to bridge always very early in the process. As soon as die is 2.5m long, up to dies that are 5m x 2.8m procurement costs, shared development costs
the gap between the engineering department we have CAD models, we start working. There long). You will see very large dies in the tool and economies of scale alongside Polestar, its
and the tooling room. Another step in may be several design models at this stage," room here. The projects that you see in the premium performance electric car brand.
digitilisation is our development towards added Kristoffer Trana. machine area are running projects (on large Simulation will play an important role in
virtual assembly (springback is an issue when helping Volvo to reduce its costs, maintain
you have narrow tolerances) – this is also A tour of the its quality standards and make the required
part of Industry- 4.0 so that parts are right tool room economies of scale to achieve this vision. n
first time with full digitilisation of the process. ISMR was given a tour of the tool room at Volvo aims to produce
We are just starting on this ladder," explained Olofström – this is a key part of the process, as many parts as
Marc Lambriks. where dies are manufactured and tryout possible from the same CONTACT
"Our productivity figures are competitive, processes can prove, or disprove, simulation die and the same For further information,
and that is largely thanks to the simulation results. To avoid logistics costs, more than see www.autoform.com
set-up. Volvo V60 at the Olofström facility
which have laid the foundation for robust one part can be made from one die set with

24 | sheetmetalplus.com | ISMR October 2019 ISMR October 2019 | sheetmetalplus.com | 25

FACE TO FACE FACE TO FACE
"For simulation compensations, our target
is within +/- 0.5mm correct from the nominal,
The ultimate aim is to have almost no spotting in
which is quite hard. If there is a mismatch
tryout, giving a result with a dimensionally between part and simulation (maybe 1mm
accurate part. off), we need to investigate which corrections
need to be done in the simulation. Small
adjustments can make a big difference.
Accuracy is everything. Die manufacturing
structural parts) which help us to learn about "The greatest challenge is to shorten the lead simulations must be accurate or everything
high-strength steel forming in-house. This is an times and deliver dies on time for the tryout and is affected. This calls for a high level of skill
important project for simulation development. we work with Kristoffer’s CAE department to and experience. A delay on one project can
You need to have the right die materials, as do the theoretical work on compensations and seriously affect the next die manufacturing
there is a lot of wear, so we use steel block milling data. We want to avoid hard geometry project," concluded Kristoffer Trana.
materials in the dies," explained Johan Nedemo, loops and the milling data must be done to
Manager, Die Process Engineering Team. ensure as short a lead time as possible for the Into the future
"It has been a great learning experience for manual grinding in the dies. So, we need to mill Volvo Cars has announced new financial and
us (we processed almost 1000 steel blocks the dies in the best possible way, with contact operational ambitions designed to position
needed to increase our efficiency). We have in the right places, and reduce manual grinding the company as a leading player in the global
also invested in three new NC milling machines so that the contact between the die and the automotive business by the middle of the
over the last three years, as well as a very large blank are in the correct position." next decade. On the operational side, it
milling machine for the larger dies." The ultimate aim is to have almost no spotting expects to generate half of all sales annually
There is constant demand for new dies, in tryout, giving a result with a dimensionally from fully electric cars, one third of all cars
Stampings at Volvo Cars
as production press lines have grown bigger. accurate part. This is what Volvo aims to sold to be autonomous driving cars and half
From a cost perspective, Volvo aims to do, learning from project to project through of all cars it offers to customers from its
produce as many parts as possible from the simulation and more. subscription service.
same die and the same set-up. "Four or five years ago, we used to do It expects these initiatives to transform its
"As a die manufacturer, we have to adapt compensations (mainly on the draw die). Now, connection to its customer base, with the aim
to that and invest more in bigger presses for we try to do individual compensations in all the of building a total of over five million direct
tryout, larger milling machines and bigger dies to ensure that the part lays stable on the consumer relationships by the middle of the
overhead cranes for lifting. We are in the lower die all the time, otherwise we will deform next decade, creating new sources of recurring
Dies are loaded into the press
middle of this investment period. When you the part when we close the dies and lose control revenue. This will also offer the company far
have big 5m dies like this, it is not a stable of the part quality," added Johan Nedemo greater potential to develop connected and
An eye on accuracy environment. The die half weighs 20 tons Today, Volvo Cars carries out a mixture of other services for customers.
"Geometrical accuracy of the part is a challenge but it still flexes, so we needed to change simulation but also physical scanning of the “Our customers’ expectations are changing
and it needs to be successful every time. We the shop floor and insert flat steel bars to part from the previous die. In the future, it aims rapidly. This means that Volvo Cars is also
have reduced the number of quality loops on support the dies, which can rest on the floor, to use mainly simulation, with not much part changing rapidly. These initiatives will help
the dies, as a result. Simulation helps us to so that there are no trim gaps and the cam scanning. It uses scanning now to evaluate transform Volvo from being purely a car
bring it down, but we need to bring it down adjustments are accurate etc. At the moment, if the simulation is correct - the best time to company to being a direct consumer services
further (repeating this exercise in the toolroom). we are digging a press pit for a new press do that is when it manufactures the dies and provider,” said Hakan Samuelsson, President
We cannot make dies for specific press lines or that we have ordered. Our plan is to make it looks the same as in the simulation. It is and Chief Executive, Volvo Cars.
presses – you never know where the part will further modifications over the next three or important to carry out the simulation and die On the financial side, Volvo Cars aims to
be produced – so robustness in the design is four years. It is a real challenge to adapt to manufacturing activities side-by-side as they generate premium level profitability in line with
key," underlined Kristoffer Trana. the die sizes,” continued Johan Nedemo. complement each other. other premium car makers, driven by increased
Although Volvo has streamlined product Die making at Volvo Cars sales and revenues across all three global sales
and process designs, elements in the process regions, and a broader range of cars including
have changed such as tolerances and stronger processes. Stamping engineering is an iterative adjustments to the die. Some car models share sales to the new segment of autonomous ride-
materials (like aluminium). Industry 4.0 will process – you change the process, you change some parts. hailing companies. The company’s improved
place even higher demands on accuracy. the part. Every part is unique. Part price is also "The moulds for small and large structural financial performance will also be driven
"In terms of Industry 4.0, as a simulation important, as is investment – much depends parts are made here and delivered to Volvo car increasingly in the future by industrial synergies
company we aim to completely digitalise the upon the volume. We are involved very early plants across the world. We produce a wide generated with its affiliated partner companies.
metal forming process chain. With the release in the car development process – stamping is range of parts from draw dies (the smallest Volvo Cars expects to benefit from lower
of AutoForm-TryoutAssistant, we try to bridge always very early in the process. As soon as die is 2.5m long, up to dies that are 5m x 2.8m procurement costs, shared development costs
the gap between the engineering department we have CAD models, we start working. There long). You will see very large dies in the tool and economies of scale alongside Polestar, its
and the tooling room. Another step in may be several design models at this stage," room here. The projects that you see in the premium performance electric car brand.
digitilisation is our development towards added Kristoffer Trana. machine area are running projects (on large Simulation will play an important role in
virtual assembly (springback is an issue when helping Volvo to reduce its costs, maintain
you have narrow tolerances) – this is also A tour of the its quality standards and make the required
part of Industry- 4.0 so that parts are right tool room economies of scale to achieve this vision. n
first time with full digitilisation of the process. ISMR was given a tour of the tool room at Volvo aims to produce
We are just starting on this ladder," explained Olofström – this is a key part of the process, as many parts as
Marc Lambriks. where dies are manufactured and tryout possible from the same CONTACT
"Our productivity figures are competitive, processes can prove, or disprove, simulation die and the same For further information,
and that is largely thanks to the simulation results. To avoid logistics costs, more than see www.autoform.com
set-up. Volvo V60 at the Olofström facility
which have laid the foundation for robust one part can be made from one die set with

24 | sheetmetalplus.com | ISMR October 2019 ISMR October 2019 | sheetmetalplus.com | 25