Abstract
A method for determining optimum blank shapes for the production of irregularly shaped prismatic shells with an arbitrarily shaped flange and stepped bottoms is proposed. All of the procedures for calculation are incorporated into a CAD system that can output the optimum blank shape in a few seconds using a personal computer. The calculation method is based on the slip-line field theory, a kinematically admissible velocity field for the flange region is determined from the theory and the calculated velocity field is used to conduct a backward calculation of the metal flow, from the designed flange shape to the initial blank shape. In the calculation it is assumed that the material is isotropic and that the thickness of the blank does not change during the deep-drawing process. A deep-drawing experiment is conducted for a square shell with six different flange shapes, using aluminum alloy sheet A5182-0 1.0mm thick and cold-rolled steel sheet SPCE 0.5mm thick. Experimental flange shapes are in good agreement with the designed (predetermined) ones. The influence of material characteristics on the blank design is found to be relatively small.
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