Abstract
This paper presents a numerical method for simultaneous optimization of blank shape and forming tool geometry in three-dimensional sheet metal forming operations. The proposed iterative procedure enables the manufacturing of sheet metal products with geometry fitting within specific tolerances (surface and edge deviations less than 0.5 or 1.0 mm, respectively) that prescribe the maximum allowable deviation between the simulated and desired geometry. Moreover, the edge geometry of the product is affected by the shape of the blank and by an additional trimming phase after the forming process. The influences of sheet metal thinning, edge geometry, and springback after forming and trimming are considered throughout the blank and tool optimization process. It is demonstrated that the procedure effectively optimizes the tool and blank shape within seven iterations without unexpected convergence oscillations. Finally, the procedure thus developed is experimentally validated on an automobile product with elaborated design and geometry which prone to large springback amounts owning to complex-phase advanced high strength steel material selection.
Highlights
We present a procedure for the simultaneous optimization of forming tool and blank shape geometry that involves adjusting the potential geometrical deviations of the product shape from its desired shape as defined in the form of the general 3D
The presented methodology for simultaneous tool and blank design optimization is applied to an automotive part made of complex-phase advanced high strength steel HDT 760C sheet, which tends to exhibit a considerable amount of springback after tool removal, owing to the high ratio of yield stress to tensile strength
We present the results of the optimization procedure, where the results refer to the forming process with the initial and the optimized tool and blank the results refer to the forming process with the initial and the optimized tool and blank designs
Summary
Mass production of manufactured sheet metal goods is nowadays subject to high standards of quality that impose strict requirements regarding the geometric tolerances and visual quality of the final product. While FEM simulations serve primarily as a tool for investigating the feasibility of a forming process in the sense of avoiding sheet metal defects [4], they can be employed as a part of the forming tool, blank shape [5], or blank thickness optimization procedures with the aim of achieving proper geometrical acceptability of the product. This enables the minimization of tool production costs through reducing the number of tool modifications or even eliminating some forming stages, such as the trimming phase [6].
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