Abstract
Today’s stamping simulations are realized by ignoring the elastic deformation of the press and tooling system through the assumption of a rigid behavior and a perfect press stroke. However, in reality, the press and tool components deform elastically and are one of the major error sources for the final adjustment and blue-spotting of the dies. In order to tackle this issue, a new approach is proposed in this study that substitutes the press stiffness by means of a substitutive model composed of cost-effective shell and beam elements. The substitute model was calibrated using full-scale measurements, in which a 20,000 kN trial press was experimentally characterized by measuring its deformation under static loads. To examine the robustness of the substitute model, a medium-size tool and a large-size tool were simulated together with the substitutive model. To this end, a B-pillar tool was re-machined based on the substitute-model results and a new cambering procedure was proposed and validated throughout the blue-painting procedure. The newly developed substitute model was able to replicate the global stiffness of the press with a high accuracy and affordable calculation time. The implementation of the findings can aid toolmakers in eliminating most of the reworking and home-line trials.
Highlights
Never before has the car industry been as challenging, interesting, and demanding as it is today
To evaluate the robustness of the newly developed substitute model, a medium-size tool and a large-size tool were simulated together with the substitutive press model and the deformations in the active surfaces of both tools were compared with the full-model-simulation results
A simple and cost-effective press-substitute model composed of low-cost shell and beam elements was developed for a 20,000 kN trial press
Summary
Never before has the car industry been as challenging, interesting, and demanding as it is today. New and advanced techniques are being introduced with increased speed in order to achieve sustainable development, improved performance, and heightened customer satisfaction This has led to increasing competition in an almost ever-expanding car market. Due to significant improvements in material models, today’s stamping-process simulations are realized by ignoring the elastic deformation of the press and tooling system by assuming a rigid behavior with a perfect press stroke, in order to reduce the numerical cost as well as the ramp-out time during the tool’s trial phase This system, including the bolster, ram, and drawing cushion, and its tools deform elastically during the stamping process, thereby forming a clearance gap between the die and the punch, which leads to a non-homogeneous pressure distribution on the part. This is becoming a critical aspect for automotive OEMs and TIER1s, since the early-stage trial in the tool shop is performed
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