- Success Stories
- 3D Scanners
- About Us
GM Daewoo Accelerates Die Duplication Using Rapidform XOR
Seoul, South Korea – Jan 15, 2008,
Replacing or duplicating a stamping die leads to unnecessary costs, inefficiencies and delays. Even though the original die has been through an exhaustive quality check, making duplicates involves more than another round of machining and assembly operations. Instead, stamping die engineers must repeat the entire die tryout process to produce quality stampings.
When General Motors announced a second Chevy Aveo production facility in Poland, the stamping die engineers at the GM Daewoo facility sought an alternative that would condense, or eliminate, the multi-week tryout process. With more than 25 large die sets for the Aveo, which is called Kalos in Korean markets, the gains in efficiency, cost reduction and lead time would be enormous.
Culminating a three year search, the GM Daewoo team found and implemented a 3D scanning procedure that uses Rapidform® XO™ scan-to-CAD software. By documenting the as-built condition of operational dies, GM Daewoo slashed die tryout times by five weeks. It also ensured that the Polish-built Aveos would have the same fit and finish as the South Korean-made Kalos.
Following CAD design and simulation, stamping dies go through a rigorous tryout process. Samples are stamped, measured and scrutinized to uncover tolerance deviations and surface defects. When flaws are discovered, the die is handworked to fine-tune it so that stampings match print specifications. For parts like the Aveo’s tailgate, the tryout process is a 16-week endeavor.
The challenge in duplicating an operational die is that the handmade adjustments create an as-built condition that no longer matches the original CAD data. Therefore, the 16-week tryout process is repeated for each replacement or duplicate die set. The ideal alternative is to eliminate this costly redundancy by measuring the die and documenting the modifications in the CAD data.
GM Daewoo’s stamping die engineers had considered both CMM and 3D scanners for the task but found each to be impractical. CMMs required too much time and labor to capture all necessary measurements. 3D scanning resolved this issue, but the scanning software could not produce surfaces sufficient for tool path creation. This lead to a cumbersome and convoluted effort that divided the point cloud processing and solid modeling efforts between two separate software programs. In the end, there was little benefit because the time saved in die tryouts was offset by the time and effort to generate the as-built CAD data.
The Chevy Aveo’s tailgate was the first sheet metal part to be stamped from a die that was duplicated using a new 3D scanning methodology. GM Daewoo converted 3D scanner point cloud information into a full-function CAD model using only Rapidform XOR™/Redesign. According to the stamping die engineers, correcting the CAD data to as-built conditions in XOR yielded an 85 to 90 percent time savings, when compared to previous 3D scanning attempts. This time savings gave them a viable solution for die duplication with minimal die tryout delays.
The GM Daewoo engineers noted that the key to making this possible was XOR’s combination of point cloud processing tools with parametric, solid modeling. In previous 3D scanning attempts, surface data was exported from the 3D scanning software and imported to UGS NX, where it was used as reference data for the manual recreation of the CAD model. In contrast, Rapidform XOR performed the CAD modeling functions. It created parametric solids, with the full history tree, that drove the automated update of GM Daewoo’s UGS NX models.
In Rapidform XOR, the die engineers used a variety of CAD Correct™ tools for refitting and redesigning the original UGS NX files. These functions were supported by the Redesign Assistant™ that aids in interpreting the design intent of features of the handworked, and slightly worn, dies. Although these functions are not available in CAD packages, the GM Daewoo team noted that the user interface was intuitive because it had a familiar, CAD-like functionality and layout.
3D Scanning for As-Built CAD
GM Daewoo selected a CogniTens Optigo scanner for the Chevy Aveo project. The Optigo captured dense point clouds that documented measurements for both the untouched and handworked features of the tailgate die set. For the four-operation stamping process, there were eight die components for drawing, punching and bending. Following scanning, the point cloud data and original UGS NX solid models were imported into Rapidform XOR. The point clouds were then cleaned, merged and aligned to the CAD model.
The first step in the CAD refitting process was identifying “regions of interest,” which are the areas where the scan data does not match the CAD model. To do so, GM Daewoo’s die engineers used Accuracy Analyzer™, which is a visual tool that highlights discrepancies between the two die descriptions. As the redesign progressed, Accuracy Analyzer also monitored the changes, in real time, to confirm that the modifications were within user-defined tolerances.
Another tool the die engineers relied on was Redesign Assistant. This XOR function automatically extracts the design intent of individual features. For example, Redesign Assistant determines the radius and center point of fillets even if there are slight changes in curvature resulting from imprecise, hand grinding or tool wear. Having extracted the design intent, the die engineers remodeled features with CAD-like solid modeling functions such as sweep, extrude and revolve.
While the standard CAD modeling functions were used throughout the project, the bulk of the time savings came from automated tools that have been developed specifically for 3D scanning. For example, GM Daewoo’s engineers turned to XOR’s automated refilleting tools. Other examples included Refit and Loft Wizard™. Refit automatically generates new, parametric faces that have G1 and G2 continuities for surface smoothness. For sculpted surfaces, the Loft Wizard automatically creates smooth, lofted surfaces and profile curves.
Manufacturing Duplicate Stamping Dies
After completing the modification of the CAD data to reflect the as-built stamping die, the parametric model, with its history tree, was transferred to UGS NX. Although time reduction for the CAD refitting process was important, the true test of this new approach to die duplication was the quality of the surfaces for machining of the production die. According to a GM Daewoo die engineer, “We have had no problems with XOR. It has proved its ability to rapidly create machinable surfaces for our body and chassis stamping dies.”
Machined from the XOR-generated solid model, the Aveo tailgate stamping die is now in operation in Warsaw, Poland. It is an exact duplicate of the Kalos die that has been stamping parts in South Korea. Replicating all of the original handworked modifications, this duplicate die is producing stampings that match the quality of the Kalos tailgate, and it is doing so without duplicating the lengthy tryout process. Using 3D scanning and Rapidform XOR, GM Daewoo cut five weeks from the tryout and approval process. For the tailgate, this 30 percent reduction resulted in an estimated savings of US$200,000. Extended over all large die sets for the Aveo, GM Daewoo estimated total saving of $5 million.
About GM Daewoo
GM Daewoo, headquartered at Incheon, South Korea, is a regional operating subsidiary of the world’s largest automobile manufacturer, GM. The company is the third largest automobile manufacturer in Korea. It manufactures small- and medium-sized passenger cars primarily catering to the Korean and other Asian markets. Among GM Daewoo’s product line-up are Matiz, Gentra X, Gentra, Lacetti, Tosca passenger cars and Winstorm SUV as well as the Damas and Labo mini commercial vehicles for export. It also produces a range of modern, highly efficient gasoline and diesel engines, transmissions. Vehicles manufactured by GM Daewoo are sold in more than 150 countries under some of the world’s most popular nameplates including Chevrolet, Buick, Pontiac and Suzuki. For more information, visit http://www.gmdaewoo.co.kr.
About INUS Technology Inc.
INUS Technology helps companies unlock the power of 3D scanning. The company’s software solutions are the most widely installed products for reverse engineering, 3D imaging and inspection using 3D scan data around the globe. Rapidform makes 3D scanning an extremely powerful tool for a variety of applications and is used in fields such as manufacturing, R&D, quality inspection, medical research and civil engineering. Leading companies including Audi, Ford, Hyundai, Toyota, Rolls Royce, Volkswagen, Hitachi, Panasonic, Oakley, Samsung, Sony, Alcoa, and Benteler use Rapidform’s advanced technology to innovate throughout their research, design, manufacturing and quality control processes. For more information, please visit http://www.rapidform.com
Tagged with: press release
- Rapidform 3D Scanning Event Attracts Record Crowd in Seoul Korea
- Rapidform XOV Adds New Probe-Based Measurement and Speeds Up Inspection
- 3D Systems Buys Rapidform
- 3D Systems Buys Geomagic
- 3D Systems Delivers Go!MODEL for Creaform Go!SCAN 3D Scanner
- 3D Systems Completes the Acquisition of Geomagic
- Rapidform Alliance Program Enables 3D Scanner Vendors to Offer Complete Hardware and Software Solutions
- New release of Rapidform XOV at EuroMold 2010
- New Release of Rapidform XOV2 Continues to Make 3D Scan-Based Verification Faster and Easier
- Rapidform to Interface Directly with Nikon Metrology Handheld Laser Scanners
- Rapidform Updates World Class 3D Scan Data Processing Tool
- Scansystems Srl becomes Rapidform 3D scanning software partner
- Rapidform Inc. Expands Into Two New Offices to Support Growing Demand
- Rapidform Sales Grow 38% as Manufacturers Adopt 3D Scanning Technology
- Rapidform XOV Helps Samsung Electronics Improve Production Quality
- Reverse Modeling Bundles FlexScan3D with Rapidform XOR
- INUS Technology Joins PTC Partner Advantage™ Program
- CGI Becomes Rapidform 3D Scanning Software Partner
- Rapidform Developer INUS Technology Receives “Great Work Place” Honor
- INUS Technology to Present Latest Releases at EuroMold 2007
- INUS Technology Wins Presidential Prize
- Latest Rapidform Products to be Displayed at INDUSTRIE2008
- Rapidform Announces Training Conference for 3D Scanning Industry Professionals
- Free 3D viewer, Rapidform® EXPLORER™ released
- INUS Technology to Present Latest Releases at Control 2009
- Breuckmann Now Offers Rapidform Software with Its 3D Scanners
- Rapidform 3D Scanning Software to be Sold with Imetric 3D Scanners
- INUS Technology to Present Latest Rapidform Scanning Solutions at EuroMold 2009
- Rapidform announces 2010 training conference for 3D scanning industry professionals
- Rapidform XOR3 Now Starts First Customer Shipment
- Calvin Hur Named CEO of INUS Technology as Simon Bae Focuses on New Products
- INUS Technology Announces H1 2010 Results; Revenue Up More Than 50%
- INUS Technology to Host 3D Scanning Industry Experts From Around the World at the Rapidform Solution Conference 2010
- INUS Technology Launches InvisHands, the First On-Demand 3D Scan-To-CAD Conversion Service
- Rapidform XOR 3D-Scanning Software Receives GOOD Software Certification
- 3DDynamics to bundle Rapidform software with the Mephisto white-light 3D scanner
- 3D Scanning Becomes Fashionable; UNITED NUDE™ High-heels Designed with Rapidform
- INUS Technology to be at CONTROL 2010, Germany
- Rapidform XOR3 Creates Native CAD Models for Six Major CAD Systems
- INUS Technology Releases InspectWorks™2.0 for Solidworks Users
- Upcoming Rapidform XOR3 Release Makes Creating CAD Models from 3D Scan Data Faster and Easier
- Rapidform 3D Scanning Software Recognized as a World Class Product by Korea’s Ministry of Knowledge Economy
- Rapidform software to be offered by DPS software, the leading European Solidworks reseller
- Steinbichler offers Rapidform Software with its scanning systems
- INUS Technology presents Latest Rapidform Solutions at DMS 2009
- Formation of Rapidform JAPAN K.K. Corporation
- Spatial PMI with CAD Translation Key Component of Rapidform Software Solution
- INUS Technology Releases Rapidform XOV/Verifier2 Inspection Software
- INUS Technology Opens Enhanced Website
- INUS Technology and Roland DG Corporation Announce OEM Agreement and Bundle Offer
- INUS Technology to Present Latest Releases at EuroMold 2008
- INUS Technology, Inc. Releases New Rapidform 3D Point-processing Libraries
- Rapidform and Creaform Announce Sales Agreement and Bundle Offer
- INUS Technology to Emphasize Automated Inspection Software at DMS 2008
- INUS Technology Sponsors The Pierre Bézier Award
- Rapidform and Metris USA Announce Sales Agreement
- INUS Technology Launches InspectWorks™ Add-in For SolidWorks
- Japan’s Nihon Unisys Excelutions Joins Rapidform Partner Program
- INNEO Solutions Joins Rapidform Partner Program
- GM Daewoo Accelerates Die Duplication Using Rapidform XOR
- Rapidform 64-bit Versions Released
- Rapidform Adds New Sales Partners to Meet Demand
- INUS Technology Releases Rapidform XOS2/Scan
- INUS Technology Releases Rapidform XOR2/Redesign
- INUS to Unveil New Rapidform Software Releases at DMS
- Rapidform.dll Delivers Powerful Mesh Processing, NURBS Surfacing and Inspection Capabilities to 3D Application Developers
- Rapidform Inc. Expands Executive Management Team for Growth
- NextEngine Unveils “Points-to-Parts” Software
- Konica Bundles VIVID 910 3D Digitizer with Rapidform XOR (US only)
- Creaform China and Rapidform Announce 3D Scanning Solutions Agreement
- Rapidform 3D Scanning Software Sales Continue Growth With Outstanding H1 2011 Results
- Hyundai Motor Accelerates Product Development with Rapidform 3D Scanning Software
- Study Finds Rapidform Is “The Only Viable Choice for Parametric Solid Modeling” from 3D Scans
- 2011 Rapidform Solution Conference Brings Together 3D Scanning Experts in Seoul, Korea
- Artec and Rapidform Join Forces to Provide World Class 3D Scanning Solutions
- Rapidform Continues European Expansion to Meet Growing Demand
- Rapidform Announces 2012 Success Conference, Annual 3D Scanning Training Event
- Record Breaking FY2011 Sales For Rapidform 3D Scanning Software
- Rapidform XOR3 SP1 Creates Native CAD Models for Autodesk Inventor
- Rapidform Releases Latest Versions of Reverse Engineering Software
- Surphaser and Rapidform Sign 3D Scanning Solutions Agreement