A 3D forming tool optimisation method considering springback and thinning compensation |
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| Affiliation: | 1. Laboratory for Numerical Modelling and Simulation, Faculty of Mechanical Engineering, University of Ljubljana, Slovenia;2. Cimos d.d., Automotive Industry, Koper, Slovenia;1. Femto-ST Institute, Department of Applied Mechanics, University of Bourgogne Franche-Comté, 25000 Besancon, France;2. PSA Group, Research and Development Division, Technique Centre of Belchamp, 25218 Montbéliard Cedex, France;1. Department of Surgery, NorthShore University HealthSystem, University of Chicago Pritzker School of Medicine, 2650 Ridge Avenue, Evanston, IL 60201, USA;2. Department of Urology, Feinberg School of Medicine, Northwestern University, 303 East Superior Avenue, Terry Building 16, Chicago, IL 60611, USA;1. Institute for Health Research, University of Bedfordshire, Putteridge Bury, Hitchin Road Luton, Bedfordshire LU2 8DL, United Kingdom;2. Head of Research and Clinical Audit, NHS Direct, Strawberry Fields, Berrywood Business Village, Tollbar Way, Hedge End, Hampshire SO30 2UN, United Kingdom;3. Department of Psychology, University of Bedfordshire, Park Square, Luton LU1 3JU, United Kingdom;4. Centre for Behavioural Medicine, UCL School of Pharmacy, BMA House, Tavistock Square, London WC1H 9JP, United Kingdom;1. Université de Lorraine, LEMTA, UMR 7563, 2 Avenue de la Forêt de Haye, TSA 60604, Vandoeuvre-lès-Nancy F54518, France;2. CNRS, LEMTA, UMR 7563, 2 Avenue de la Forêt de Haye, TSA 60604, Vandoeuvre-lès-Nancy F54518, France;3. Now at: Université d’Evry, Laboratoire de Mécanique et d’Energtique d’Evry, 40 rue du Pelvoux, CE1455 Courcouronnes, 91020 Evry Cédex, France;1. School of Power and Mechanical Engineering, Wuhan University, Wuhan, Hubei Province, China;2. College of Pipeline and Civil Engineering, China University of Petroleum, Qingdao, Shandong Province, China;3. School of Civil Engineering, Hunan University of Technology, Zhuzhou, Hunan Province, China |
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| Abstract: | In this paper, an enhanced numerical method for forming tool design optimisation in three-dimensional (3D) sheet metal forming applications is presented. The applied procedure enables a determination of appropriate forming tool geometry so that the manufacture of a sheet metal product inside specified tolerances would be ensured. In addition to the springback that occurs in the formed part after removal of the forming tools, the impact of the thinning of the sheet metal during the forming process is considered in the method, and both effects are correspondingly compensated for an iterative procedure. Computational efficiency in the E-DA-3D method is achieved mainly because the improved accuracy of the communicated data established corresponding interrelations between the discretised topologies used in the definition of the prescribed product geometry, the current tool geometry, and on this basis actually computed product geometry which is achieved by means of additional point topology mappings. The potential and effectiveness of the method is demonstrated by considering two cases of the forming tool design optimisation that are also experimentally validated. |
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| Keywords: | Tool design Sheet metal forming Optimisation Springback compensation Experimental validation |
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