Adaptable tooling sets for metal forming of geometrically similar products

Abstract

This paper presents the concept of a layered tooling structure for flexible metal forming tools. The adaptation of tooling geometry is possible through such layered tooling sets. The active forming tool parts are built with multiple layers, with layer thicknesses ranging from 1 to 20 mm and more. Layers are manufactured with conventional cutting technologies and/or three-dimensional laser beam cutting, wire electro-discharge machining (wire EDM) or abrasive water jet cutting (AWJ). The production times of new tool sets can also be shortened using existing tool plates. The developed optimisation model for the design of tool layers used in the crafting of new layered tools for metal forming, or the redesign of existing ones, consists of many significant parameter groups: geometrical parameters, tool load parameters, tooling material and tool set assembly. The geometry of layered tooling sets is chosen on the basis of these parameters and tested with regard to the accessibility of tooling materials. The developed system for the optimisation of tooling design has been verified via the redesign of a laminated deep drawing die for rotational cups used for the production of cups with several different diameters. The tooling set redesign, tool plate geometry, and clamping and positioning methods have been chosen on the basis of all the affected parameters. The tool geometry defined with the optimisation system was analysed using finite-element method (FEM) simulations in order to verify the geometry with respect to the defined forming process. Last but not least, deep drawing experiments were performed to confirm the geometry of the chosen tooling set and forming process parameters achieved by FEM simulation.