Numerically Efficient Sheet Metal Forming Simulations in Consideration of Tool Deformation

Song, Yun Jun; Oh, In Suk; Hwang, Sang Hee; Choi, Heeseon; Lee, Myoung‐Gyu; Kim, Hyung Jong

doi:10.1007/s12239-021-0008-4

Cited by 6 publications

(2 citation statements)

References 13 publications

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“…In [6,[26][27][28][29], the forming simulation based on the geometry of the active surface of the die is performed in PAM-Stamp. Then a separate elastic structural simulation model of the die, punch, and blankholder was created.…”

Section: Coupled Fe Modelsmentioning

confidence: 99%

An overview of Methods for Simulating Sheet Metal Forming with Elastic Dies

Pilthammar,

Sigvant,

Islam

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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Sheet metal forming (SMF) simulations are traditionally carried out with rigid active forming surfaces. This means that the elasticity and dynamics of presses and die structures are ignored. The only geometries of the tools included in the simulations are the active forming surfaces. One reason for this simplification is the large amount of computational power that is required to solve finite element (FE) models that incorporates elastic stamping dies. Another reason is the lack of die CAD models before the later stages of stamping projects. Research during the last couple of decades indicated potential large benefits when including elastic dies in SMF simulations. For example, for simulating die try-out or for Digital Twins of presses and dies. Even though the need and potential benefits of elastic dies in simulations are well known it is not yet implemented on a wide scale. The main obstacles have been lacking data on presses and dies, long simulation times, and no standardized implementation in SMF software. This paper presents an overview of existing methods for SMF simulations with elastic dies and discuss their respective benefits and drawbacks. The survey of methods shows that simulation models with elastic tools will be needed for detailed analyses of forming operations and also for purposes like digital twins. On the other hand, simplified and robust models can be developed for non-FEA users to carry out simple one-step compensation of tool surfaces for virtual spotting purposes. The most promising and versatile method from the literature is selected, modified, and demonstrated for industrial sized dies.

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Section: Coupled Fe Modelsmentioning

confidence: 99%

An overview of Methods for Simulating Sheet Metal Forming with Elastic Dies

Pilthammar,

Sigvant,

Islam

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

View full text Add to dashboard Cite

show abstract

“…Moreover, cutting forces during machining can cause tool deformation, which subsequently affects the surface finish and dimensions of machined parts [ 12 ], leading to a reduction in the machine tool’s machining accuracy [ 13 ]. Tool deformation is highly significant for designing tool geometry and determining optimal cutting conditions [ 14 ], as well as being crucial for the part’s forming quality [ 15 ]. Given that this paper focuses on finishing machining with small machining parameters, tool deformation during machining can be considered negligible.…”

Section: Introductionmentioning

confidence: 99%

A Multi-Scale Tool Orientation Generation Method for Freeform Surface Machining with Bull-Nose Tool

Dong

Song

et al. 2023

Micromachines

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Free-form surface parts are widely used in industries, and they consist of intricate 3D surfaces such as molds, impellers, and turbine blades that possess complex geometrical contours and demand high precision. Proper tool orientation is crucial for ensuring the efficiency and accuracy of five-axis computer numerical control (CNC) machining. Multi-scale methods have received much attention and have been widely used in various fields. They have been proven to be instrumental and can obtain fruitful outcomes. Ongoing research on multi-scale tool orientation generation methods, which aim to acquire tool orientations that satisfy both macro- and micro-scale requirements, is significantly important for improving the machining quality of workpiece surfaces. This paper proposes a multi-scale tool orientation generation method that considers both the machining strip width and roughness scales. This method also ensures a smooth tool orientation and avoids interference in the machining process. First, the correlation between the tool orientation and rotational axis is analyzed, and feasible area calculation and tool orientation adjustment methods are introduced. Then, the paper introduces the calculation method for machining strip widths on the macro-scale and the roughness calculation method on the micro-scale. Besides, tool orientation adjustment methods for both scales are proposed. Next, a multi-scale tool orientation generation method is developed to generate tool orientations that meet the macro- and micro-scale requirements. Finally, to verify the effectiveness of the proposed multi-scale tool orientation generation method, it is applied to the machining of a free-form surface. Experimental verification results have shown that the tool orientation generated by the proposed method can obtain the expected machining strip width and roughness, meeting both macro- and micro-scale requirements. Therefore, this method has significant potential for engineering applications.

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