A method for simultaneous optimization of blank shape and forming tool geometry in sheet metal forming simulations

Starman, Bojan (author), Cafuta, Gašper (author), Mole, Nikolaj (author)

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.

• Language: English
• Keywords: sheet metal forming, blank shape, tool design, optimisation, experimental validation
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2021
• Number of pages: 19 str.
• Numbering: Vol. 11, iss. 4, art. 544
• PID: 20.500.12556/RUL-135363
• UDC: 519.8:621.98.04(045)
• ISSN on article: 2075-4701
• DOI: 10.3390/met11040544
• COBISS.SI-ID: 57420803
• Publication date in RUL: 09.03.2022

Record is a part of a journal

• Title: Metals
• Shortened title: Metals
• Publisher: MDPI AG
• ISSN: 2075-4701
• COBISS.SI-ID: 15976214

Licences

• License: CC BY 4.0, Creative Commons Attribution 4.0 International
• Link: http://creativecommons.org/licenses/by/4.0/
• Description: This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.
• Licensing start date: 01.04.2021

Secondary language

• Language: Slovenian
• Keywords: preoblikovanje pločevine, platina, zasnova orodja, optimizacija, eksperimentalna validacija

Projects

• Funder: ARRS - Slovenian Research Agency
• Project number: P2-0263
• Name: Mehanika v tehniki