Topology optimization and lightweight design of stamping dies for forming automobile panels

Abstract

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.

Lightweight design of temporary support device of rectangular shield for the robot system of coal mine roadway excavation

“…They carried out a structure-material integrated lightweight design, which achieved a weight reduction of 4.12 kg, with a weight reduction rate of 1.32%, and reduced the material cost. From the aspect of structural lightweight, Su et al 10 adopted the topology optimization method to ensure the reliability of the structure and realize a lightweight design of the stamping die parts by approximately 18%. Simultaneously, the die structure was redesigned according to the manufacturing technology and initial optimization results to ensure the manufacturability of the new structure.…”

Experimental and numerical studies on bending characteristics of woven CFRP reinforced aluminum thin-walled automotive structures

“…2,3 Higher energy absorption efficiency per unit mass is obtained by optimizing process parameters such as spot welds or forming. 4,5 In addition, scholars have proposed novel agent models and large-scale multi-objective optimization methods for structural crashworthiness of lightweight materials. [6][7][8] 1 School of Mechanical Engineering, Hebei University of Technology, Tianjin, China 2 Among the new lightweight materials, carbon fiber reinforced plastic (CFRP) has the advantages of low density, high strength, superior energy absorption and flexible design, which could balance lightweight and crashworthiness requirements of auto body structure simultaneously.…”

“…2,3 Higher energy absorption efficiency per unit mass is obtained by optimizing process parameters such as spot welds or forming. 4,5 In addition, scholars have proposed novel agent models and large-scale multi-objective optimization methods for structural crashworthiness of lightweight materials. 6–8…”

Topological Design of a Hinger Bracket Based on Additive Manufacturing

“…Currently, topology optimization technology is the main way to achieve a lightweight design. Topology optimization technology is the realization of the on-demand distribution of materials within a component's structure based on an optimal force transfer path to achieve the most efficient structural performance while providing good economic benefits [5,6]. With the emergence of the homogenization method, continuum topology optimization methods have rapidly been developed, gradually forming into variable density methods, including solid isotropic material with penalization (SIMP) [7,8] and rational approximation of material properties (RAMP) [9][10][11], evolutionary structural optimization (ESO) [12,13], and level set (LS) [14,15].…”