Abstract
This work presents a new virtual method for the optimised thermal design of hot stamping tools. It provides optimal positions of the tool's tempering ducts with respect to the average working temperature and its homogeneous distribution on the surface of a tool. It consists of a specific procedure for hot stamping tool design and a software framework in order to interconnect three domains: (I) a parametrised CAD tool model, (II) a linear thermal solver using a fast boundary element method and (III) an optimisation algorithm. This enables the automated set-up, simulation and optimisation of a duct topology. The boundary conditions for the simulations are derived from a reduced model of the thermal loading of the tool. The virtual method proposed is demonstrated on simplified tool segment geometries. The results are transferred to complex tool designs used in industry. For a selected use case, the number of ducts could be reduced by 50% through the application of the proposed method. These results are validated virtually based on an existing design. Hence, the new virtual method contributes to a CAE-driven tool design and a more efficient tool manufacturing.
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