scholarly journals Blank Shape Optimization Considering 3D Space Targets for External and Internal Boundaries in Sheet Metal Forming Processes

2021 ◽  
Author(s):  
Hamidreza Gharehchahi ◽  
Mohammad Javad Kazemzadeh-Parsi ◽  
Ahmad Afsari ◽  
Mehrdad Mohammadi
Keyword(s):  
Shape Optimization ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
3D Space ◽  
Blank Shape Optimization ◽  
Blank Shape

scholarly journals Blank shape optimization considering 3D space targets for external and internal boundaries in sheet metal forming processes

2021 ◽  
Author(s):  
Hamidreza Gharehchahi ◽  
Mohammad Javad Kazemzadeh-Parsi ◽  
Ahmad Afsari ◽  
Mehrdad Mohammadi
Keyword(s):  
Sheet Metal ◽  
Optimum Design ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Production Costs ◽  
Internal Boundary ◽  
Optimum Shape ◽  
Plastic Behavior ◽  
3D Space ◽  
Blank Shape

Abstract The optimum design of an initial blank shape in sheet metal forming processes is an important step in many industries, especially automobile manufacturers because it reduces production costs and material waste. To the best of our knowledge, no research has been conducted on the blank shape designs based on 3D space target contours. Moreover, the present study considers parts with internal boundaries and optimum design of the internal boundary, which are among the innovations of this research. By following the iterative simulation-based optimization process, a special updating algorithm was proposed to modify the blank geometry in each iteration and reach the optimum shape. The sheet forming was severely nonlinear, due to plastic behavior, large deformations, and frictional contact surfaces. Therefore, the updating formula should be robust enough to be insensitive to the initial guess for the blank. To evaluate the proposed updating formula, some numerical examples were solved and the results were presented. Finally, the robustness of the proposed algorithm was investigated in these numerical experiences, by considering different geometries, target contours, internal boundaries, and initial guesses. The present study reveals that the proposed algorithm can be effectively used to solve blank optimization problems for the deep drawing process.

scholarly journals Blank Shape Design for Sheet Metal Forming based on Geometrical Resemblance

2014 ◽  
Vol 81 ◽  
pp. 1487-1492 ◽  
Author(s):  
Chen Yang ◽  
Peng Li ◽  
Lixia Fan
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Shape Design ◽  
Blank Shape

A new approach of die shape optimization for sheet metal forming processes

2004 ◽  
Vol 152 (1) ◽  
pp. 35-42 ◽  
Author(s):  
Xiaoxiang Shi ◽  
Jun Chen ◽  
Yinghong Peng ◽  
Xueyu Ruan
Keyword(s):  
Shape Optimization ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
New Approach

scholarly journals A Method for Simultaneous Optimization of Blank Shape and Forming Tool Geometry in Sheet Metal Forming Simulations

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 544
Author(s):  
Bojan Starman ◽  
Gašper Cafuta ◽  
Nikolaj Mole
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Material Selection ◽  
Three Dimensional ◽  
Simultaneous Optimization ◽  
Tool Geometry ◽  
Forming Process ◽  
Edge Geometry ◽  
Blank Shape

This paper presents a numerical method for simultaneous optimization of blank shape and forming tool geometry in three-dimensional sheet metal forming operations. The proposed iterative procedure enables the manufacturing of sheet metal products with geometry fitting within specific tolerances (surface and edge deviations less than 0.5 or 1.0 mm, respectively) that prescribe the maximum allowable deviation between the simulated and desired geometry. Moreover, the edge geometry of the product is affected by the shape of the blank and by an additional trimming phase after the forming process. The influences of sheet metal thinning, edge geometry, and springback after forming and trimming are considered throughout the blank and tool optimization process. It is demonstrated that the procedure effectively optimizes the tool and blank shape within seven iterations without unexpected convergence oscillations. Finally, the procedure thus developed is experimentally validated on an automobile product with elaborated design and geometry which prone to large springback amounts owning to complex-phase advanced high strength steel material selection.

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