Optimisation of Die Radius Geometry in Sheet Metal Stamping

Abstract

Advanced high strength steels (AHSS) are increasingly utilised in sheet metal stamping in the automotive manufacture. In comparison with conventional steels, AHSS stampings produce higher contact pressures at the interface between the tool-workpiece interface, leading to more severe wear conditions, particularly at the draw die radius. To minimise tool wear using this approach it would be necessary to optimise the shape for a particular combination of circular and high elliptical profiles. This paper presents a methodology to optimise a die radius profile. For this, a specialised software routine is developed and compiled for optimisation of die radius profiles to minimise or achieve uniform contact pressure (wear distribution) using Python computer programming language supported by Abaqus software. A detailed algorithm for the optimisation is explained. A case study based on the algorithm is also discussed.