Structural Design of an Auto Panel Die Component Based on the Contact Pressure Using Topology Optimization

2020 ◽  
Vol 1158 ◽  
pp. 165-176
Author(s):  
Fatih Koşar ◽  
Kemal Yaman
Keyword(s):  
Topology Optimization ◽  
Contact Pressure ◽  
Static Solution ◽  
Service Condition ◽  
Die Design ◽  
Von Mises Stress ◽  
Thickness Variation ◽  
Die Geometry ◽  
Stamping Die ◽  
Auto Panel

The main motivation in stamping die industry and academia is panel quality and formability issues rather than the weight and cost of the die. A product should be designed according to the loads that it can be faced in service condition. But somehow this rule is not valid for stamping die design since the minimum distance between the ribs is based on the standards and location and pattern of the ribs which are depending primarily on the company experience. In this work, an auto panel drawing die design is investigated numerically whether it is overdesigned or not. The loads on the die surfaces are calculated by numerical methods. When a panel is drawn between upper and lower die, the contact pressure (CP) occurs on the interface surfaces due to this interaction. Since CP is a vital parameter and it is almost impossible to measure it by experimental methods, it is validated by two different numerical codes. The CP values obtained from Autoform® quasi-static solution are compared with Abaqus® transient forming analysis solution. Topology optimization is applied on the lower die by using the estimated CP loads. Von-Mises stress, elastic deformation and volume are compared between current and optimized die geometry. Panel thickness variation is also investigated in longitudinal and transverse directions.

scholarly journals Elasto-plastic analysis of the contact region between a rigid ellipsoid and a semi-flat surface

2018 ◽  
Vol 10 (9) ◽  
pp. 168781401879739 ◽  
Author(s):  
Pengyang Li ◽  
Lingxia Zhou ◽  
Fangyuan Cui ◽  
Quandai Wang ◽  
Meiling Guo ◽  
...  
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
Plastic Strain ◽  
Contact Pressure ◽  
Contact Region ◽  
Three Dimensional ◽  
Von Mises Stress ◽  
Effective Plastic Strain ◽  
Normal Forces ◽  
Von Mises

When the load acting on a mechanical structure is greater than the yield strength of the material, the contact surface will undergo plastic deformation. Cumulative plastic deformation has an important influence on the lifespan of mechanical parts. This article presents a three-dimensional semi-analytical model based on the conjugate gradient method and fast Fourier transform algorithm, with the aim of studying the characteristic parameters of the contact region between a rigid ellipsoid and elasto-plastic half-space. Moreover, normal forces and tangential traction were considered, as well as the contact pressure resulting from various sliding speeds and friction coefficients. The contact pressure, effective plastic strain, von Mises stress, and residual stress were measured and shown to increase with increasing sliding velocity. Finally, when the friction coefficient, contact pressure, and effective plastic strain are increased, the von Mises stress is also shown to increase, whereas the residual stress decreases.

scholarly journals Evaluation of induced residual stresses on AISI 1020 low carbon steel plate from experimental and FEM approach during TIG welding process

2019 ◽  
Vol 13 (1) ◽  
pp. 4415-4433
Author(s):  
I. B. Owunna ◽  
A. E. Ikpe
Keyword(s):  
Carbon Steel ◽  
Residual Stresses ◽  
Steel Plate ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Service Condition ◽  
Tig Welding ◽  
Von Mises Stress ◽  
Low Carbon ◽  
Temperature Range

Induced residual stresses on AISI 1020 low carbon steel plate during Tungsten Inert Gas (TIG) welding process was evaluated in this study using experimental and Finite Element Method (FEM). The temperature range measured from the welding experimentation was 251°C-423°C, while the temperature range measured from the FEM was 230°C-563°C; whereas, the residual stress range measured from the welding experimentation was 144MPa-402Mpa, while the residual range measured from the FEM was 233-477MPa respectively. Comparing the temperature and stress results obtained from both methods, it was observed that the range of temperature and residual stresses measured were not exactly the same due to the principles at which both methods operate but disparities between the methods were not outrageous. However, these values can be fed back to optimization tools to obtain optimal parameters for best practices.  Results of the induced stress distribution was created from a static study where the thermal results were used as loading conditions and it was observed that the temperature increased as the von-Mises stress increased, indicating that induced stresses in welded component may hamper the longevity of such component in service condition. Hence, post-weld heat treatment is imperative in order to stress relieve metals after welding operation and improve their service life.

A new methodology for thermostructural topology optimization: Analytical definition and validation

2020 ◽  
pp. 146442072097024
Author(s):  
R Caivano ◽  
A Tridello ◽  
M Codegone ◽  
G Chiandussi
Keyword(s):  
Topology Optimization ◽  
Heat Exchangers ◽  
Mechanical Performance ◽  
Turbine Blades ◽  
Mathematical Formulation ◽  
Service Condition ◽  
Manufacturing Processes ◽  
Structural Topology ◽  
Real Component ◽  
Rapid Diffusion

In the last few years, the rapid diffusion of components produced through additive manufacturing processes has boosted the research on design methodologies based on topology optimization algorithms. Structural topology optimization is largely employed since it permits to minimize the component weight and maximize its stiffness and, accordingly, optimize its resistance under structural loads. On the other hand, thermal topology optimization has been less investigated, even if in many applications, such as turbine blades, engines, heat exchangers, thermal loads have a crucial impact. Currently, structural and thermal optimizations are mainly considered separately, despite the fact that they are both present and coupled in components in service condition. In the present paper, a novel methodology capable of defining the optimized structure under simultaneous thermomechanical constraints is proposed. The mathematical formulation behind the optimization algorithm is reported. The proposed methodology is finally validated on literature benchmarks and on a real component, confirming that it permits to define the topology, which presents the maximized thermal and mechanical performance.

Design of Energy Absorbing Structure Using Topology Optimization With a Multi-Material Model

2003 ◽  
Author(s):  
Daeyoon Jung ◽  
Hae Chang Gea
Keyword(s):  
Topology Optimization ◽  
Strain Energy ◽  
Effective Properties ◽  
Service Condition ◽  
Material Model ◽  
Three Phase ◽  
The Mean ◽  
Energy Absorbing ◽  
Dual Objectives ◽  
Mean Compliance

To accommodate the dual objectives of many engineering applications, one to minimize the mean compliance for the stiffest structure under normal service condition and the other to maximize the strain energy for energy absorption during excessive loadings, topology optimization with a multi-material model is applied to the design of energy absorbing structure in this paper. The effective properties of the three-phase material are derived using a spherical micro-inclusion model. The dual objectives are combined in a ratio formation. Numerical examples from the proposed method are presented and discussed.

Geometric compensation for automotive stamping die design integrating structure deflection and blank thinning

2012 ◽  
Vol 66 (9-12) ◽  
pp. 1449-1456 ◽  
Author(s):  
Jun Chen ◽  
Dongkai Xu ◽  
Guodong Xia ◽  
Xifeng Li ◽  
Jieshi Chen ◽  
...  
Keyword(s):  
Die Design ◽  
Stamping Die

Design and Analysis on a Kind of Oblique-Cone-Slid-Ring Assembly Seal Device with Self-Compensation to Seal Wear in Carbide Actor

2010 ◽  
Vol 43 ◽  
pp. 247-252 ◽  
Author(s):  
Yong Hu ◽  
Wei Yan ◽  
Hua Bing Wen ◽  
Chuan Shun Wen
Keyword(s):  
Work Stress ◽  
Contact Stress ◽  
Von Mises Stress ◽  
Thickness Variation ◽  
Ansys Software ◽  
Ring Assembly ◽  
Spring Force ◽  
User Demand ◽  
Von Mises ◽  
Oblique Cone

We design and analyze a kind of oblique-cone-slid-ring (OCSR) assembly seal device used in carbide actor that can self-compensate the seal wear. The effect of the OCSR thickness variation on the contact stress, Von mises stress, and spring force is analyzed using ANSYS software. It shows that the OCSR assembly seal device can seal well and has the function of self-compensation to seal wear when the OCSR thickness vary during the experiment conditions given. The max contact stress on the seal surface and other contact face is higher or much higher than the work stress of sealed medium. That means the design is satisfied with the user demand. The results provide a theoretical base for the further study and applications of the OCSR assembly seal device.

Collaborative Aluminum Profile Design to Adaptable Die Process Planning Using Neural Networks

2010 ◽  
Vol 443 ◽  
pp. 207-212 ◽  
Author(s):  
Suthep Butdee ◽  
Chaiwat Noomtong ◽  
Serge Tichkiewitch
Keyword(s):  
Neural Network ◽  
Process Planning ◽  
Collaborative Design ◽  
Die Design ◽  
Machining Process ◽  
Aluminum Extrusion ◽  
Product Data ◽  
Die Geometry ◽  
Extrusion Die ◽  
Profile Design

Aluminum extrusion die manufacturing is a critical task for productive improvement and increasing potential of competition in aluminum extrusion industry. It causes to meet the efficiency not only consistent quality but also time and production cost reduction. Die manufacturing consists first of die design and process planning in order to make a die for extruding the customer’s requirement products. The efficiency of die design and process planning are based on the knowledge and experience of die design and die manufacturer experts. This knowledge has been formulated into a computer system called the knowledge-based system. It can be reused to support a new die design and process planning. Such knowledge can be extracted directly from die geometry which is composed of die features. These features are stored in die feature library to be prepared for producing a new die manufacturing. Die geometry is defined according to the characteristics of the profile, is called product data, so we can reuse die features from the previous similar profile design cases. This paper presents the artificial neural network to assist aluminum extrusion die design and process planning based on collaborative design methodology. Product data can be shared and distributed in die design team members via computer network technology. This product data is used to support die design and process planning. Die manufacturing cases in the case library would be retrieved with searching and learning method by neural network for reusing or revising it to build a die design and process planning when a new case is similar with the previous die manufacturing cases. The results of the system are dies design and machining process.

scholarly journals Combined shape and topology optimization for minimization of maximal von Mises stress

2017 ◽  
Vol 55 (5) ◽  
pp. 1541-1557 ◽  
Author(s):  
Haojie Lian ◽  
Asger N. Christiansen ◽  
Daniel A. Tortorelli ◽  
Ole Sigmund ◽  
Niels Aage
Keyword(s):  
Topology Optimization ◽  
Von Mises Stress ◽  
Shape And Topology Optimization ◽  
And Topology ◽  
Von Mises
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