Optimal Blank Design for the Drawings of Arbitrary Shapes by the Sensitivity Method

2000 ◽  
Author(s):  
H. B. Shim ◽  
K. C. Son
Keyword(s):  
Shape Sensitivity ◽  
Initial Blank ◽  
Blank Design ◽  
Door Panel ◽  
Explicit Analysis ◽  
Simulation And Experiment ◽  
Deformation Processes ◽  
Final Deformation ◽  
Blank Shape ◽  
Sensitivity Method

Abstract The sensitivity method in order to find initial blank shapes which result in desired shapes after deformation has been used in this study.. By assuming the final deformation shape be the drawn cup with uniform trimming allowance at the flange, the corresponding initial blank which gives final shape after deformation has been found. With the aid of a well-known dynamic explicit analysis code PAM-STAMP, shape sensitivity has been obtained. To get the shape sensitivity numerically, a couple of deformation processes have been analyzed. Drawings of trapezoidal cup, oil pan, and Audi front door panel, the benchmark test problem of Numisheet ’99 have been chosen as the examples. At every case the optimal blank shape has been obtained only a few times of modification without predetermined deformation path. With the predicted optimal blank, both computer simulation and experiment are performed. Excellent agreements are recognized between simulation and experiment at every case. Through the investigation the sensitivity method is found to be very effective in the arbitrary shaped drawing process design.

Optimal Blank Design for the Drawings of Arbitrary Shapes by the Sensitivity Method

2000 ◽  
Vol 123 (4) ◽  
pp. 468-475 ◽  
Author(s):  
H. B. Shim ◽  
K. C. Son
Keyword(s):  
Shape Sensitivity ◽  
Initial Blank ◽  
Blank Design ◽  
Door Panel ◽  
Explicit Analysis ◽  
Simulation And Experiment ◽  
Deformation Processes ◽  
Final Deformation ◽  
Blank Shape ◽  
Sensitivity Method

The sensitivity method is employed in this work in order to find initial blank shapes which result in desired shapes after deformation. By assuming the final deformation shape be the drawn cup with uniform trimming allowance at the flange, the corresponding initial blank which gives the desired final shape after deformation has been found. With the aid of a well-known dynamic explicit analysis code PAM-STAMP, shape sensitivity has been obtained. To get the shape sensitivity numerically, a couple of deformation processes have been analyzed. Drawings of trapezoidal cup, oil pan, and Audi front door panel, the benchmark test problem of Numisheet ’99, have been chosen as the examples. In every case the optimal blank shape has been obtained after only a few modifications without a predetermined deformation path. With the predicted optimal blank, both computer simulation and experiment are performed. Excellent agreements are obtained between simulation and experiment in every case. Through this investigation, the sensitivity method is found to be very effective in the design of arbitrary shaped drawing processes.

Optimal blank shape design by the iterative sensitivity method

2002 ◽  
Vol 216 (6) ◽  
pp. 867-878 ◽  
Author(s):  
H Shim ◽  
K Son
Keyword(s):  
Moving Boundary ◽  
Shape Change ◽  
Design Stage ◽  
Shape Error ◽  
Shape Sensitivity ◽  
Initial Shape ◽  
Target Shape ◽  
Blank Design ◽  
Blank Shape ◽  
Sensitivity Method

In order to realize net shape manufacturing of drawn parts, determination of the optimal blank shape plays a key role in the process development stage. The sensitivity method has many successful applications of the optimal blank design. In the method, the undeformed blank shape is modified iteratively by moving boundary nodes in the initial moving direction until the deformed shape satisfies a target shape. To determine the magnitude of the movement of the nodes, both the shape error measured at the deformed shape and the shape sensitivity defined by the effect of initial shape change on the final shape are utilized. To obtain shape sensitivity for each boundary node numerically, a couple of deformation processes has been analysed at each design stage with an original blank and offset blank. Drawings of the trapezoidal cup, cross-shaped cup and oil pan have been chosen as examples to verify the sensitivity method. Both the cross-shaped cup and oil pan are examples of complicated material flow during forming while the trapezoidal cup is of a simple flow. For every case the optimal blank shape has been obtained after only a few modifications without any predetermined deformation path. With the predicted optimal blank, a corresponding experiment has been carried out. The deformed shapes of the experiment almost exactly coincide with the desired target shape in every case. Through the investigation, the sensitivity method is found to be excellent in the blank design of arbitrary shaped drawing products.

Investigation of the Effect of Blank Shape on the Sheet Hydroforming Parameters

2012 ◽  
Vol 152-154 ◽  
pp. 1658-1663
Author(s):  
S. Ali Zamani ◽  
Morteza Hosseinzadeh
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Trial And Error ◽  
Systematic Method ◽  
Explicit Analysis ◽  
Simulation And Experiment ◽  
Blank Shape ◽  
Trial And Error Method ◽  
Cylindrical Cup ◽  
Error Method

In the deep drawing processes, the use of an optimal blank shape not only saves the material but also it may reduce the occurrence of defects e.g. wrinkling and tearing. In addition, finding the desirable flange contour, eliminate the trimming step in the deep drawing of parts with flange. The main objective of this study is to optimize the blank shape in order to produce a cylindrical cup with desirable flange contour and investigation of its effect on important parameters. Presently, to overcome this issue, a very expensive and time consuming trial and error method is used. In this study, a systematic method based on sensitivity analysis has been used to find the optimal blank to obtain a desirable flange contour for a cylindrical cup by hydromechanical deep drawing process. With the aid of a well-known dynamic explicit analysis code ABAQUS; optimum initial blank shape has been obtained. With the predicted optimal blank, both computer simulation and experiment are performed and the effect of blank shape on the some parameters such as thickness distribution and forming pressure of the formed cups were investigated. It is shown that formed cup with an optimum blank shape has a better thickness distribution in the rolled direction.

Blank Shape Design Based on Inverse Finite Element Method Using Ideal Forming Theory and a Modified Kinematics Formulation

Volume 3 ◽  
2004 ◽  
Author(s):  
Mohammad Habibi Parsa ◽  
Payam Pournia
Keyword(s):  
Deformation Gradient ◽  
Design Procedure ◽  
Deformation Gradient Tensor ◽  
Specific Product ◽  
Initial Blank ◽  
Blank Design ◽  
Material Element ◽  
One Step ◽  
Blank Shape ◽  
The Ideal

For stamping of sheet metals and converting them to specific product shapes without failure, the initial blanks should be correctly designed. Otherwise, final products will not be sound. So initial blank design is a critical step in stamping design procedure. In the present paper for calculating the total deformation gradient and its relation to each step’s deformation gradient tensor (F), a modified kinematics formulation will be introduced. This formulation has been used in connection with the ideal forming theory for predicting the initial blank shape of the specified products with defined blank thickness. In the ideal forming theory, each material element is prescribed to deform in a minimum plastic work path and ideal process is obtained when the deformations are most evenly distributed in the final products. The later has been assumed for developing a FEM code to predict the blank shape and size in one step, which has been applied for three different kinds of stampings, cylindrical, square and clover shape cups. The results show the capability of the new algorithm in designing the initial blank shape for stamping products.

Blank Design by ANN in Bimetallic Deep Drawing

2009 ◽  
Author(s):  
M. R. Morovati Mamaghani ◽  
B. M. Dariani ◽  
M. Haddadzade
Keyword(s):  
Neural Network ◽  
Deep Drawing ◽  
Training Data ◽  
Raw Material ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Initial Blank ◽  
Blank Design ◽  
Novel Approach ◽  
Blank Shape

The present paper deals with the initial blank design of bimetallic parts obtained by deep drawing process. Normally in deep drawing, the initial blank has a simple shape and after drawing, its perimeter shape will become very complex and has considerable influences on the forming results. If the initial blank shape is designed in such a way that is formed into the desired shape after the drawing process, not only it reduces the time of trimming process, but also decreases the drawing force and the raw material needed substantially. The present paper proposes a novel approach to initial blank optimization in multilayer deep drawing. The Finite Element Method (FEM) is employed for simulating multilayer plate deep drawing process to provide training data for Artificial Neural Network (ANN). The aim of the neural network is to predict the initial blank shape for the desired final shape. The FEM results were verified through experiment.

Computational Methods for the Design of Deformation Processes of Porous Materials

2002 ◽  
Author(s):  
Nicholas Zabaras ◽  
Shankar Ganapathysubramanian
Keyword(s):  
Porous Materials ◽  
Thermal Analyses ◽  
Computational Design ◽  
Design Problems ◽  
Sensitivity Equations ◽  
Material State ◽  
Deformation Processes ◽  
Continuum Sensitivity ◽  
Updated Lagrangian ◽  
Sensitivity Method

An updated Lagrangian framework of the continuum sensitivity method (CSM) is presented to address important computational design problems in the deformation processing of porous materials. Weak sensitivity equations are developed that are consistent with the kinematic, constitutive, contact and thermal analyses used in the solution of the direct thermomechanical problem. The CSM is here used to analyze die and preform computational design problems in industrial metal forming processes wherein temperature and the accumulated damage play an important role in influencing the deformation mechanism, material state and shape of the deformed workpiece.

Blank Shape Optimization in Deep Drawing with Combined Restraint

2013 ◽  
Vol 371 ◽  
pp. 178-182
Author(s):  
Viorel Paunoiu ◽  
Virgil Teodor
Keyword(s):  
Numerical Simulation ◽  
Deep Drawing ◽  
Degree Of Deformation ◽  
Initial Blank ◽  
Mathematical Relation ◽  
Blank Shape Optimization ◽  
Cylindrical Parts ◽  
Blank Shape ◽  
High Degree

One of the methods for increasing the degree of deformation in the deep drawing of the cylindrical parts is the method with the combined restraint. In this process, due to the high degree of deformation, the earing is pronounced and affects the quality of the final part. The paper focuses in optimization the blank shape in this process applying a method which combines a mathematical relation with the results of the numerical simulation. The mathematical relation connects the radii of the initial blank at the different angles with the sizes of the part heights at different angles. The numerical simulation using FEM was used for the heights determination at the main anisotropy directions considering different initial blank dimensions. An experimental work was done for certify the numerical results. The results confirmed that the optimization of the blank shape in deep drawing with the combined restraint is a key for improving the deformation process, for reduction the earing and for minimizing the material consumption.

Research on the Blank Design Method of Closed Rolling the High-Neck Flange

2011 ◽  
Vol 314-316 ◽  
pp. 594-598
Author(s):  
Min Xiao ◽  
Xue Dao Shu
Keyword(s):  
Numerical Simulation ◽  
Mathematical Model ◽  
Design Method ◽  
Scientific Basis ◽  
Shape Design ◽  
Blank Design ◽  
Rolling Method ◽  
Blank Shape ◽  
Blank Size ◽  
The Mathematical Model

Blank shape design is the prerequisite and foundation of optimization for the closed forming the high-neck flange. This paper obtained the design formulas of blank size with analyzing the mathematical model of flank blank based on the principle of volume invariably during the rolling process.The blank of a special flange was designed by this method which was validated by the numerical simulation under the DEFORM software. The results indicate that the product is qualified with the blank shape based on this method. These research conclusions can provide scientific basis for forming the high-neck flange with rolling method.

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