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Rochester Hills
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Rochester Hills Assembly

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Rochester Hills - Design office

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Die Design and Die Process

Founded in 1945 with 67 years design experience in Tandem, Cross Bar and Tri-Axis Dies. Leader in quality and performance with dicult tooling. Procient in CATIA V5 and NX (UniGraphics). 25 seats of CaTa 20 seats of NX (UniGraphics) 32 Engineers Averaging 22.4 years of design experience Parts ranging from Body Sides to Reinforcements We provide lean Die Processes in 2D and 3D. Instrumental in reducing number of dies needed by customers. Able to reduce commissioning from days to hours and eliminate last minute machining during a Tme sensiTve home line tryout.
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Die Process

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Die Process

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1ST TRIM DIE LOWER ASSEMBLY

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1ST TRIM DIE UPPER ASSEMBLY

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1ST CAM FORM DIE LOWER ASSEMBLY

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1ST CAM FORM DIE UPPER ASSEMBLY

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2ND CAM FORM DIE LOWER ASSEMBLY (POST REMOVED)

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2ND CAM FORM DIE UPPER ASSEMBLY PAD REMOVED

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FLANGE & CAM FLANGE DIE WITH ROTOR CAMS LOWER ASSEMBLY

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Beginning of time until the early to mid 1980s

Paper 2D fully dimensioned drawings (50+ sheets per design) MILES and MILES of vertical drawing boards Reference ONLY! (Pre-Manufacturable) Non-standard designer-to-designer Wood patterns and duplicator shops Full surfacing and NC programming departments 16-20 weeks for major panels
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Mid 1980s to 2009

3D and 2.5D designs (Still some detailing) Only a couple of MILES of boards Reference ONLY! 3D patterns for the most part Full Surfacing and NC programming Some 2D programming layout benefits Simple CAD tools to promote efficiency Improved standardization designer-to-designer 8-12 weeks for major panels
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2009 to Today
True 3D die designs (No more boards) Virtually manufacturable die designs Reduced need for NC programmers and surfacers Complete 3D pattern models Advanced CAD tools that aide in delivering die designs that not only save time, but mirror the actual end Product Standardization and greater value 4-6 weeks for major panels
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CHRYSLER PF BODYSIDE OUTER FORM DIE

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Past

SECTION A-A (PRE-MANUFACTURABLE DESIGNS)

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Present

UPPER PAD

CAM PAD

LOWER POST CAM FORM STEEL

0.69mm METAL THICKNESS

FILL SLIDE
0.8mm PAD TO STEEL CLEARANCE

CAM SLIP PAD

SECTION A-A
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Past

UPPER PAD

CAM PAD LOWER POST

CAM TRIM STEEL

SECTION B-B (PRE-MANUFACTURABLE DESIGNS)

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Present

UPPER PAD

LOWER POST

0.69mm METAL THICKNESS

CAM PAD

0.069mm TRIM BREAKAGE

CAM TRIM STEEL

SECTION B-B
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MODELING FILE CONTAINING REQUIRED SHEET WORK

PARAMETERS ARE USED TO CONTROL SURFACE OFFSETS

GEOMETRICAL SETS CREATED TO CONTAIN THE WORK REQUIRED TO MAKE A REQUIRED SHEET

SURFACE MODELING STRUCTURE

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SURFACING FOR DIE COMPONENT ARE PUBLICATED OUT AND LINKED TO SOLID MODEL FILES.

EACH SHEET IS SPECIFICALLY NAMED SO THAT NC PROGRAMING CAN AUTOMATICALLY USE THE DATA.

PUBLICATIONS FOR SOLID MODELING

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A SOLID BODY OF THE PANEL COMING IN TO THE DIE IS CREATED FOR INTERFERENCE CHECKS AND TO PROPERLY REPRESENT THE PANEL BEFORE THE OPERATION.

INCOMING OPERATIONAL PANEL

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A SOLID BODY OF THE PANEL COMING OUT OF THE DIE IS CREATED TO ACCURATLY SHOW THE PANEL AFTER THE OPERATION IS COMPLETE.

OUTGOING OPERATIONAL PANEL

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3D DIE PROCESSES ARE CREATED TO ENSURE THAT DIES ARE COMPLETELY COVERING THE OPERATION.

VIEW Y

VIEW X 3D DIE PROCESS

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TRIM BYPASS NOTCHES SHOWN ACCURATLY

VIEW X
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FLANGE TRANSITION

FLANGE ROLLOUTS PROPERLY MODELED TO SHOW WHAT IS HAPPENING FROM DIE TO DIE

VIEW Y
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SCREWS, DOWELS, JACKSCREWS AND JIG JACK SCREWS ARE SHOWN

REQUIREMENTS FOR DIE COMPONENTS

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REMOVES FOR TAPS AND REAMS IN MATING COMPONENT ARE LINKED OUT DETAIL REQUIREMENTS FOR DIE COMPONENTS
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SURFACES REQUIRED FOR MACHING ARE SPECIFICALLY NAMED AND PUBLISHED OUT OF THE DETAIL.

REQUIREMENTS FOR DIE COMPONENTS

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BAR STOCK DETAILS ARE MODELED STARTING WITH A BODY THAT MATCHES THE ORDERED STOCK SIZE 88.9mm 3.5 INCHES

152.4mm 6 INCHES

76.2mm 3 INCHES REQUIREMENTS FOR DIE COMPONENTS

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WEAR PLATES ARE MODELED LOW SIDE OF TOLERANCE. THIS ALLOWS AUTODIE TO SIZE THE PLATE WITH OUT PUTTING THE CASTING BACK ON A MACHINE

99.75mm

100mm X 200mm WEAR PLATE

STANDARD ITEMS
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THANK YOU!

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