A deformation based blank design method for formed parts

Abstract

Blank design is an important task in sheet metal forming process optimization. The initial blank shape has direct effect on the part quality. This paper presents a deformation based blank design approach to determine the initial blank shape for a formed part. The blank design approach is integrated separately into ABAQUS, and DD3IMP, a research purpose in-house FEA code, to demonstrate its compatibility with any FEA code. The algorithm uses FE results to optimize the blank shape for a part. Deep drawing simulation of a rectangular cup geometry was carried out with an initial blank shape determined empirically. The blank shape was iteratively modified, based on the deformation history, until an optimal blank shape for the part is achieved. The optimal blank shapes predicted by the algorithm using both FEA softwares were similar. Marginal differences in the shape error indicate that the deformation history based push/pull technique can effectively determine an optimal blank shape for a part with any FEA software. For the shape error selected, both procedures estimate the optimal blank shape for the part within five iterations.

Evaluation of piezoelectric energy harvester under dynamic bending by means of hybrid mathematical/isogeometric analysis

“…Moreover, the algorithm samples of CAD's spline model integration with finite element software, i.e. ABAQUS, can be seen in (Hammami et al 2009;Lai et al 2017b).…”

A Method for Optimal Blank Shape Determination in Sheet Metal Forming Based on Numerical Simulations

“…Furthermore, correction of each edge point is computed by applying a scaling factor between 0.5 and 0.9, its actual value being defined by a ratio of the initial velocity to the total deformation path length. In [24], Hamammi et al propose a method where the blank shape correction is made in the direction described by the positions of each node lying on the blank edge at the beginning and at the end of the forming process. Another method, where the correction of the blank shape is also based on taking the displacement path of the product edge nodes into account, is proposed by Fazli and Arezoo in [25].…”

“…Another method, where the correction of the blank shape is also based on taking the displacement path of the product edge nodes into account, is proposed by Fazli and Arezoo in [25]. They proved that their method is slightly better in terms of accuracy and also in convergence than the previous two methods, [23] and [24].…”

Optimization of Initial Blank Shape with a Variable Blank Holder Force in Deep-Drawing via Sequential Approximate Optimization

“…It is important to design and optimize the initial blank shape so as to reduce the earing without the geometrical defect. It is also possible to avoid wrinkling and tearing through the forming process with optimum initial blank shape (1)(2)(3)(4)(5)(6)(7)(8) . In order to determine the optimum initial blank shape, many papers with numerical simulation have been published.…”

“…Lin and Kwan applied an abductive network with the FEA to predict the initial blank shape for minimizing earing (7) . Hammami et al proposed a deformation based approach to determine the initial blank shape called push/pull technique (8) . Many approaches consider the earing minimization to reduce the waste of material, and much time-consuming simulation runs are required.…”