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

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.

Blank Optimization in Elliptical-Shape Sheet Metal Forming Using Response Surface Model Coupled with Reduced Basis Technique and Finite Element Analysis

2011 ◽  
Vol 473 ◽  
pp. 683-690 ◽  
Author(s):  
Khalil Khalili ◽  
Parviz Kahhal ◽  
Ehsan Eftekhari Shari ◽  
M. Soheil Khalili
Keyword(s):  
Finite Element ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Shape Design ◽  
Drawing Process ◽  
Reduced Basis ◽  
Element Analysis ◽  
Design Variables ◽  
Blank Shape

The present study aims to determine the optimum blank shape design for the deep drawing of Elliptical-shape cups with a uniform trimming allowance at the flange i.e. cups without ears. This earing defect is caused by planar anisotropy in the sheet and the friction between the blank and punch/die. In this research, a new method for optimum blank shape design using finite element analysis has been proposed. Present study describes the approach of applying Response Surface Methodology (RSM) with Reduced Basis Technique (RBT) to assist engineers in the blank optimization in sheet metal forming. The primary objective of the method is to reduce the enormous number of design variables required to define the blank shape. RBT is a weighted combination of several basis shapes. The aim of the method is to find the best combination using the weights for each blank shape as the design variables. A multi-level design process is developed to find suitable basis shapes or trial shapes at each level that can be used in the reduced basis technique. Each level is treated as a separated optimization problem until the required objective – minimum earing function – is achieved. The experimental design of RSM method is used to build the approximation model and to perform optimization. MATLAB software has been used for building RSM model. Explicit non-linear finite element (FE) Code Abaqus/CAE is used to simulate the deep drawing process. FE models are constructed incorporating the exact physical conditions of the process such as tooling design like die profile radius, punch corner radius, etc., material used, coefficient of friction, punch speed and blank holder force. The material used for the analysis is Stainless steel St12. A quantitative earing function is defined to measure the amount of earing and to compare the deformed shape and target shape set for each stage of the analysis. The cycle is repeated until the converged results are achieved. This iterative design process leads to optimal blank shape. So through the investigation the proposed method of optimal blank design is found to be very effective in the deep drawing process and can be further applied to other stamping applications.

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.

The Blank Optimization of an Automotive Fender Skirt in the Process of Sheet Metal-Forming Based on one-Step Simulation Method

2013 ◽  
Vol 634-638 ◽  
pp. 2904-2908
Author(s):  
Yu Ping Zhang ◽  
Jie Wei Hong
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Simulation Method ◽  
Forming Simulation ◽  
One Step ◽  
Blank Shape ◽  
Mould Design ◽  
3D Software ◽  
Simulated Analysis

This article puts forward One-step forming simulation method to solve blank outline problems in the process of sheet metal forming. The blank outline curve is got from the simulated analysis of Groupware of Fender by one-step simulation in Dynaform 3D software for sheet forming, considering the final shape of the workpiece. It simulates three programs via three different shapes of blanks. And it compares and analyze the FLD diagram and forming results ,and then it gets the optimized blank shape. This way guides the mould design, and save the time of repairing moulds on the basis of producing qualified products. It overcomes the puzzle how to choose the blanks’ size and shape.

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