Forming tools in Solidworks - Dashboard Guide

Dashboard Mode - Forming tools

Business Question

How can we analyze the performance and usage of different forming tools in our manufacturing process to improve efficiency and reduce costs?

Sample Data: Forming Tools Usage

Tool ID	Tool Name	Usage Hours	Number of Parts Produced	Maintenance Cost ($)	Last Maintenance Date
FT001	Hydraulic Press	120	1500	500	2024-05-10
FT002	Mechanical Punch	95	1300	300	2024-04-20
FT003	Roll Forming Machine	140	1700	450	2024-05-05
FT004	Stretch Forming Tool	80	1100	200	2024-03-30
FT005	Press Brake	110	1400	350	2024-05-01

Dashboard Components

• KPI Card: Total Usage Hours
  Formula: SUM of Usage Hours = 120 + 95 + 140 + 80 + 110 = 545 hours
• KPI Card: Total Parts Produced
  Formula: SUM of Number of Parts Produced = 1500 + 1300 + 1700 + 1100 + 1400 = 7000 parts
• KPI Card: Total Maintenance Cost
  Formula: SUM of Maintenance Cost = 500 + 300 + 450 + 200 + 350 = $1800
• Bar Chart: Usage Hours by Tool
  X-axis: Tool Name
  Y-axis: Usage Hours
  Values: [120, 95, 140, 80, 110]
• Bar Chart: Parts Produced by Tool
  X-axis: Tool Name
  Y-axis: Number of Parts Produced
  Values: [1500, 1300, 1700, 1100, 1400]
• Table: Detailed Tool Data
  Shows all columns from sample data for detailed review

Dashboard Layout

+--------------------------------------------------+
| Total Usage Hours | Total Parts Produced | Total  |
|      (545 hrs)    |      (7000 parts)    |Maintenance|
|                   |                      |  Cost   |
|                   |                      |  ($1800) |
+--------------------------------------------------+
| Usage Hours by Tool (Bar Chart)                  |
| +----------------------------------------------+ |
| | FT001 | FT002 | FT003 | FT004 | FT005        | |
| | 120   | 95    | 140   | 80    | 110          | |
| +----------------------------------------------+ |
+--------------------------------------------------+
| Parts Produced by Tool (Bar Chart)               |
| +----------------------------------------------+ |
| | FT001 | FT002 | FT003 | FT004 | FT005        | |
| | 1500  | 1300  | 1700  | 1100  | 1400         | |
| +----------------------------------------------+ |
+--------------------------------------------------+
| Detailed Tool Data (Table)                        |
| Tool ID | Tool Name          | Usage | Parts |...|
| FT001   | Hydraulic Press    | 120   | 1500  |...|
| FT002   | Mechanical Punch   | 95    | 1300  |...|
| FT003   | Roll Forming Machine | 140   | 1700  |...|
| FT004   | Stretch Forming Tool | 80    | 1100  |...|
| FT005   | Press Brake        | 110   | 1400  |...|
+--------------------------------------------------+
  

Interactivity

Filter by Tool Name: Selecting a tool filters the bar charts and the detailed table to show only data for that tool.

Date Filter: Filtering by Last Maintenance Date updates the detailed table and KPIs to reflect only tools maintained after the selected date.

Usage Hours Range Slider: Adjusting this slider filters tools shown in charts and table by their usage hours.

Self Check

If you add a filter to show only tools with Usage Hours greater than 100, which components update and what data do they show?

• The KPI cards update to sum only tools with Usage Hours > 100: FT001 (120), FT003 (140), FT005 (110). Total Usage Hours = 370, Total Parts Produced = 1500 + 1700 + 1400 = 4600, Maintenance Cost = 500 + 450 + 350 = 1300.
• The bar charts update to show only these three tools.
• The detailed table shows only FT001, FT003, and FT005 rows.

Key Result

Dashboard shows forming tools usage, parts produced, and maintenance costs with interactive filters for detailed analysis.

Practice

1. What is the primary purpose of forming tools in SolidWorks sheet metal design?

easy

A. To shape metal by pressing without cutting

B. To cut metal into separate pieces

C. To paint the metal surface

D. To measure metal thickness

Solution

1. Step 1: Understand forming tools function

   Forming tools shape sheet metal by pressing, not cutting or removing material.

2. Step 2: Compare options with definition

   Only To shape metal by pressing without cutting describes shaping by pressing; others describe cutting, painting, or measuring.

3. Final Answer:

   To shape metal by pressing without cutting -> Option A

4. Quick Check:

   Forming tools = shaping by pressing [OK]

Hint: Remember: forming tools press, they don't cut [OK]

Common Mistakes:

• Confusing forming tools with cutting tools
• Thinking forming tools paint or measure metal
• Assuming forming tools remove material

2. Which of the following is the correct way to create a forming tool in SolidWorks?

easy

A. Use the Weldments > Insert > Forming Tool command

B. Use the Assembly > Insert > Forming Tool command

C. Use the Surface > Insert > Forming Tool command

D. Use the Sheet Metal > Insert > Forming Tool command

Solution

1. Step 1: Identify correct menu path for forming tools

   Forming tools are part of sheet metal features, so they are under Sheet Metal menu.

2. Step 2: Match options with correct menu

   Only Use the Sheet Metal > Insert > Forming Tool command uses Sheet Metal > Insert > Forming Tool, others use unrelated menus.

3. Final Answer:

   Use the Sheet Metal > Insert > Forming Tool command -> Option D

4. Quick Check:

   Forming tools = Sheet Metal menu [OK]

Hint: Forming tools are always under Sheet Metal menu [OK]

Common Mistakes:

• Selecting wrong menu like Weldments or Assembly
• Confusing forming tools with surface features
• Trying to insert forming tools in assemblies

3. Given a sheet metal part with a forming tool feature that creates a dimple, what will happen if you increase the depth parameter of the forming tool?

medium

A. The dimple will become shallower and less visible

B. The dimple will become deeper pressing more into the metal

C. The dimple will be removed from the part

D. The metal thickness will increase

Solution

1. Step 1: Understand depth parameter effect

   Increasing depth means pressing the forming tool further into the metal, making the dimple deeper.

2. Step 2: Analyze options

   Only The dimple will become deeper pressing more into the metal correctly describes deeper dimples; others describe incorrect effects.

3. Final Answer:

   The dimple will become deeper pressing more into the metal -> Option B

4. Quick Check:

   Depth up = dimple deeper [OK]

Hint: More depth means deeper shape [OK]

Common Mistakes:

• Thinking depth reduces dimple size
• Assuming forming tools remove features
• Believing metal thickness changes with depth

4. You created a forming tool but it does not appear on your sheet metal part after insertion. What is the most likely cause?

medium

A. The forming tool sketch is not fully defined

B. The forming tool is not saved as a part file

C. The forming tool feature is suppressed

D. The sheet metal thickness is zero

Solution

1. Step 1: Check forming tool visibility

   If the forming tool feature is suppressed, it will not appear on the part.

2. Step 2: Evaluate other options

   Sketch definition or saving issues usually cause errors, not invisibility; zero thickness is invalid but different problem.

3. Final Answer:

   The forming tool feature is suppressed -> Option C

4. Quick Check:

   Suppressed feature = invisible forming tool [OK]

Hint: Check if forming tool feature is suppressed [OK]

Common Mistakes:

• Ignoring feature suppression status
• Assuming sketch issues hide forming tool
• Confusing file saving with feature visibility

5. You want to create a forming tool that adds ribs to a sheet metal part. Which steps should you follow to ensure the ribs form correctly and simulate manufacturing?

hard

A. Create a forming tool part with rib shapes, save it, then insert it into the sheet metal part using Insert > Forming Tool, ensuring the tool thickness matches the sheet metal thickness.

B. Draw ribs directly on the sheet metal part without using forming tools.

C. Use the weldment feature to add ribs instead of forming tools.

D. Create a surface feature for ribs and convert it to a forming tool.

Solution

1. Step 1: Create forming tool part with rib shapes

   Design the rib shapes in a separate part file to use as a forming tool.

2. Step 2: Insert forming tool into sheet metal part

   Use Insert > Forming Tool command and ensure tool thickness matches sheet metal thickness for correct forming.

3. Final Answer:

   Create a forming tool part with rib shapes, save it, then insert it into the sheet metal part using Insert > Forming Tool, ensuring the tool thickness matches the sheet metal thickness. -> Option A

4. Quick Check:

   Forming tool part + insert + thickness match = correct ribs [OK]

Hint: Match forming tool thickness to sheet metal thickness [OK]

Common Mistakes:

• Skipping forming tool creation and drawing ribs directly
• Using weldments instead of forming tools for ribs
• Trying to convert surface features to forming tools