Blank optimization for sheet metal forming using multi-step finite element simulations
Blank optimization for sheet metal forming using multi-step finite element simulations
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DOI：
10.1007/s00170-008-1383-y
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发表时间：
2009-02
期刊：
影响因子：
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通讯作者：
Jyhwen Wang;A. Goel;Fengchen Yang;J. Gau
中科院分区：
文献类型：
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作者：
Jyhwen Wang;A. Goel;Fengchen Yang;J. Gau
本研究旨在确定任意形状杯形件拉深的最佳毛坯形状设计，在凸缘处具有均匀的切边余量，即，没有耳朵的杯子凸耳或非均匀凸缘是由板料中的非均匀材料流动和平面各向异性引起的。本研究提出一种利用有限元素分析进行最佳化毛坯形状设计的新方法。变形过程首先分为多个步骤。定义形状误差度量以测量制耳量并比较变形形状和针对分析的每个阶段设置的目标形状。然后使用该误差度量来决定是否需要修改毛坯。毛坯几何形状的变化基于材料流。重复该循环，直到获得收敛的结果。这种迭代设计过程导致最佳的毛坯形状。为了验证所提出的方法，杯形件拉深的三个例子。在每一种情况下，收敛的结果后，几次迭代。所提出的系统化的毛坯优化设计方法被发现是非常有效的拉深工艺，并可以进一步应用到其他金属板成形应用，如冲压工艺。
The present study aims to determine the optimum blank shape design for deep drawing of arbitrary shaped cups with a uniform trim allowance at the flange, i.e., cups without ears. The earing, or non-uniform flange, is caused by non-uniform material flow and planar anisotropy in the sheet. In this research, a new method for optimum blank shape design using finite element analysis is proposed. The deformation process is first divided into multiple steps. A shape error metric is defined to measure the amount of earing and to compare the deformed shape and target shape set for each stage of the analysis. This error metric is then used to decide whether the blank needs to be modified. The blank geometry change is based on material flow. The cycle is repeated until the converged results are achieved. This iterative design process leads to optimal blank shape. To test the proposed method, three examples of cup drawing are presented. In every case converged results are achieved after a few iterations. The proposed systematic method for optimal blank design is found to be very effective in the deep drawing process and can be further applied to other sheet metal forming applications such as stamping processes.