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Automotive Design & Manufacturing Intensive
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Module 4
Day 4: Sheet Metal Stamping & APQP Fundamentals
1
Sheet Metal Stamping: Stages and Sequence
Describe the sheet metal stamping process stages (blanking, drawing, trimming, flanging) and their sequence.
Describe the sheet metal stamping process stages (blanking, drawing, trimming, flanging) and their sequence.
2
Automotive Metals: Strength & Formability
Compare common automotive sheet metals (mild steel, HSLA, DP steel, aluminum) based on strength and formability.
Compare common automotive sheet metals (mild steel, HSLA, DP steel, aluminum) based on strength and formability.
3
Stamping Defect Analysis and Mitigation
Identify common stamping defects (springback, wrinkling, tearing) and explain how process controls mitigate them.
Identify common stamping defects (springback, wrinkling, tearing) and explain how process controls mitigate them.
4
Sheet Metal Design: Golden Rules for Manufacturing
Apply golden rules for sheet metal design, including bend radii for high-strength steel, hole-to-edge distance, and minimum flange length.
Apply golden rules for sheet metal design, including bend radii for high-strength steel, hole-to-edge distance, and minimum flange length.
5
Unfolding 3D Models: K-Factor & Bend Allowance
Calculate a flat pattern from a 3D model using K-factor and bend allowance principles.
Calculate a flat pattern from a 3D model using K-factor and bend allowance principles.
6
APQP Phases, Gates, and Design Reviews
Describe the five phases of APQP and how phase gates connect to design reviews and validation builds.
Describe the five phases of APQP and how phase gates connect to design reviews and validation builds.
7
Integrating DFM, DFMEA, and GD&T in APQP
Explain where DFM, DFMEA, and GD&T deliverables fit within the APQP timeline.
Explain where DFM, DFMEA, and GD&T deliverables fit within the APQP timeline.
Previous module
Day 3: Complex Interior Trim Assembly & ECO Implementation
Next module
Day 5: Design of a Stamped Automotive Bracket