The accurate prediction of deformation and stress distribution on the stamping die components is critical to guarantee structure reliability and lightweight design. This work aims to propose a new method based on numerical simulation for predicting die structural behaviors and reducing total weight. The sheet metal forming simulation was rstly conducted to obtain the accurate forming contact force during stamping process. The linear static structural analysis with different load cases was then performed to investigate the deformation and stress distribution on die structure. Topology optimization was employed to realize lightweight design while ensuring structural safety. Redesign process for die structures was conducted according to both manufacturing techniques and initial optimized results to guarantee the manufacturability of new structures. The proposed methodology has several advantages of decreasing model scale, precluding intricate contact condition settings as well as time-saving. A long beam stamping die used for forming automobile panels was selected to validate the proposed methodology, and around 18% weight reduction was achieved.

The accurate prediction of deformation and stress distribution on the stamping die components is critical to guarantee structure reliability and lightweight design. This work aims to propose a new method based on numerical simulation for predicting die structural behaviors and reducing total weight. The sheet metal forming simulation was firstly conducted to obtain the accurate forming contact force during stamping process. The linear static structural analysis with different load cases was then performed to investigate the deformation and stress distribution on die structure. Topology optimization was employed to realize lightweight design while ensuring structural safety. Redesign process for die structures was conducted according to both manufacturing techniques and initial optimized results to guarantee the manufacturability of new structures. The proposed methodology has several advantages of decreasing model scale, precluding intricate contact condition settings as well as time-saving. A long beam stamping die used for forming automobile panels was selected to validate the proposed methodology, and around 18% weight reduction was achieved.