Top

International Journal of Material Forming

Published in:

28-11-2021 | Original Research

Optimum blank shape design in deep drawing process using a new boundary updating formula

Authors: Hamidreza Gharehchahi, Mohammad-Javad Kazemzadeh-Parsi, Ahmad Afsari, Mehrdad Mohammadi

Published in: International Journal of Material Forming | Issue 6/2021

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

Blank design is an important task in sheet metal forming process optimization. The initial blank shape has direct effect on improving the part quality, reducing the cost of production, time, waste and improve the thickness distribution in the production part. This paper presents a new iteration based method for optimizing the shape of a blank in the deep drawing process. Also three other iteration based algorithms reported in the literature are described briefly. The optimum blank shapes for some case studies are obtained using each algorithm and the results are compared. The general solution to optimum blank design is use numerical simulation iterative based methods. The present study implements a similar approach and presents a new algorithm to make geometrical corrections to the external boundaries of a blank in several iterations. In this paper, numerical simulation of the deep drawing process based on the finite element method is performed using Abaqus software and a computer program was developed to automatically run these iterations to study the features of the proposed method. The results indicate that the algorithm developed in the current work is more efficient.

previous article Springback prediction and validation in hot forming of a double-curved component in alloy 718

next article Part-optimized forming by spatially distributed vaporizing foil actuators

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

inform now

Hazek V, Lange K (1979) Use of the slip-line method in deep drawing of large irregular shaped components. In: Proceedings of the 7th North American Metalwork Research Conference, SME, pp 65–71

Lange K, Gloeckl H (1983) Computer aided design of blanks for deep drawn irregular shaped components. In: Proceedings of the 11th North American Manufacturing Research Conference, SME, pp 243–251

Sowerby R, Chandrasekharan N, Chen X, Rooks M, Correa P (1988) The development of computer aids for sheet metal stampings. In: Ghosh SK, Niku-Lari A (eds)CAD/CAM and FEM in Metal working, 3rd International Conference on SAS, Pergamon Press, Oxford, p 187

Karima M (1989) Blank development and tooling design for drawn parts using a modified slip line field based approach. J Eng Ind Trans ASME 111:345–350. https://doi.org/10.1115/1.3188770CrossRef

Vogel JH, Lee D (1990) An analytical method for deep drawing process design. Int J Mech Sci 32(11):891–907. https://doi.org/10.1016/0020-7403(90)90062-NCrossRef

Chen X, Sowerby R (1992) The development of ideal blank shapes by the method of plane stress characteristics. Int J Mech Sci 2:159–166. https://doi.org/10.1016/0020-7403(92)90080-ZCrossRef

Chen X, Sowerby R (1996) Blank development and the prediction of earing in cup drawing. Int J Mech Sci 38:509–516. https://doi.org/10.1016/0020-7403(95)00068-2CrossRefMATH

Kuwabara T, Si WH (1997)PC-based blank design system for deep drawing irregularly shaped prismatic shells with arbitrarily shape flange. J Mater Process Technol 63:89–94. https://doi.org/10.1016/S0924-0136(96)02605-2CrossRef

Parsa MH, Matin PH, Mashhadi MM (2004) Improvement of initial blank shape for intricate products using slip line field. J Mater Process Technol 145:21–26. https://doi.org/10.1016/S0924-0136(03)00858-6CrossRef

10.

Kim N, Kobayashi S (1986) Blank design in rectangular cup drawing by an approximate method. Int J Mach Tool Des Res 26:125–135. https://doi.org/10.1016/0020-7357(86)90213-1CrossRef

11.

Sowerby R, Duncan JL, Chu E (1986) The modeling of sheet metal stampings. Int J Mech Sci 28:415–430. https://doi.org/10.1016/0020-7403(86)90062-7CrossRef

12.

Blount GN, Fischer BV (1995) Computerized blank shape prediction for sheet metal components having doubly-curved surfaces. Int J Prod Res 33:993–1005. https://doi.org/10.1080/00207549508930190CrossRefMATH

13.

Zaky AM, Nassr AB, El-Sebaie MG (1998) Optimum blank shape of cylindrical cups in deep drawing of anisotropic sheet metal. J Mater Proc Technol 76:203–211. https://doi.org/10.1016/S0924-0136(97)00349-X

14.

Chung K, Richmond O (1992) Ideal forming II. Sheet forming with optimum deformation. Int J Mech Sci 34:617–633. https://doi.org/10.1016/0020-7403(92)90059-PCrossRefMATH

15.

Iseki H, Sowerby R (1995) Determination of the optimal blank shape when deep drawing non axisymmetric cups using a finite element method. Jap Soc Mech Eng Int A 38:473–479. https://doi.org/10.1299/jsmea1993.38.4_473CrossRef

16.

Barlat O, Batoz JL, Guo Y, Q, Mercier F, Naceur H, Knopf-Lenoir C (1996) Optimum blank design of blank contours using the inverse approach and a mathematical programming technique. In: Proceedings of Numisheet, 96, pp 178–185

17.

Lee CH, Huh H (1997) Blank design and strain prediction of automobile stamping parts by an inverse finite element approach. J Mater Proc Technol 63:645–650. https://doi.org/10.1016/S0924-0136(96)02700-8

18.

Guo YQ, Batoz JL, Naceur H, Bouabdallah S, Mercier F, Barlet O (2000) Recent developments on the analysis and optimum design of sheet metal forming parts using a simplified inverse approach. Comput Struct 78:133–148. https://doi.org/10.1016/S0045-7949(00)00095-XCrossRef

19.

Ku TW, Lim HJ, Choi HH, Hwang SM, King BS (2001) Implementation of backward tracing scheme of the FEM to blank design in sheet metal forming. J Mater Proc Technol 111:90–97. https://doi.org/10.1016/S0924-0136(01)00518-0

20.

Naceur H, Guo YQ, Batoz JL (2004) Blank optimization in sheet metal forming using an evolutionary algorithm. J Mater Proc Technol 151:183–191. https://doi.org/10.1016/j.jmatprotec.2004.04.036

21.

Cai ZY, Li MZ, Zhang HM (2007) A simplified algorithm for planar development of 3D surface and its application in the blank design of sheet metal forming. Finite Elem Anal Des 43:301–310. https://doi.org/10.1016/j.finel.2006.10.005CrossRef

22.

Parsa MH, Pournia P (2007) Optimization of initial blank shape predicted based on inverse finite element method. Finite Elem Anal Des 43:218–233. https://doi.org/10.1016/j.finel.2006.09.005CrossRef

23.

Azizi R, Assempour A (2008) Applications of linear inverse finite element method in prediction of the optimum blank in sheet metal forming. Mater Des 29:1965–1972. https://doi.org/10.1016/j.matdes.2008.04.015CrossRef

24.

Azizi R (2009) Different implementations of inverse finite element method in sheet metal forming. Mater Des 30:2975–2980. https://doi.org/10.1016/j.matdes.2008.12.022CrossRef

25.

Toh CH, Kobayashi S (1985) Deformation analysis and blank design in square cup drawing. Int J Mach Tool Des Res 25:15–32. https://doi.org/10.1016/0020-7357(85)90054-XCrossRef

26.

Chung K, Barlat F, Brem JC, Lege DJ, Richmond O (1997) Blank shape design for a planar anisotropic sheet based on ideal forming design theory and FEM analysis. Int J Mech Sci 39:105–120. https://doi.org/10.1016/0020-7403(96)00007-0CrossRefMATH

27.

Park SH, Yoon JW, Yang DY, Kim YH (1999) Optimum blank design in sheet metal forming by the deformation path iteration method. Int J Mech Sci 41:1217–1232. https://doi.org/10.1016/S0020-7403(98)00084-8CrossRefMATH

28.

Pegada V, Chun Y, Santhanam S (2002) An algorithm for determining the optimal blank shape for the deep drawing of aluminum cups. J Mater Proc Technol 125–126:743–750. https://doi.org/10.1016/S0924-0136(02)00382-5

29.

Shim H, Son K (2002) Optimal blank shape design by the iterative sensitivity method. Proc IMECHE Part B J Eng Manuf, 216, 867–878. https://doi.org/10.1243/095440502320192996

30.

Son KC, Shim HB (2003) Optimal blank shape design using the initial velocity of boundary nodes. J Mater Process Technol 134:92–98CrossRef

31.

Vafaeesefat A (2008) Optimum blank shape design in sheet metal forming by boundary projection method. Int J Mater Form 1:189–192. https://doi.org/10.1007/s12289-008-0023-2CrossRef

32.

Azaouzi M, Naceur H, Delame´ziere A, Batoz JL, Belouettar S (2008) A heuristic optimization algorithm for the blank shape design of high precision metallic parts obtained by a particular stamping process. Finite Elem Anal Des 44:842–850. https://doi.org/10.1016/j.finel.2008.06.008CrossRef

33.

Hammami W, Padmanabhan R, Oliveira MC, BelHadjSalah H, Alves JL, Menezes LF (2009) A deformation based blank design method for formed parts. Int J Mech Mater Des 5:303–314. https://doi.org/10.1007/s10999-009-9103-9CrossRef

34.

Padmanabhan R, Oliveira MC, Baptista AJ, Alves JL, Menezes LF (2009) Numerical study on the influence of initial anisotropy on optimal blank shape. Finite Elem Anal Des 45:71–80. https://doi.org/10.1016/j.finel.2008.07.012CrossRef

35.

Fazli A, Arezoo B (2012) A comparison of numerical iteration based algorithms in blank optimization. Finite Elem Anal Des 50:207–216. https://doi.org/10.1016/j.finel.2011.09.011CrossRef

36.

Gharehchahi H, Kazemzadeh-Parsi MJ, Afsari A et al (2021) Blank shape optimization in the deep drawing process by sun method. Prod Eng Res Devel. https://doi.org/10.1007/s11740-021-01049-zCrossRef

Title: Optimum blank shape design in deep drawing process using a new boundary updating formula
Authors: Hamidreza Gharehchahi
Mohammad-Javad Kazemzadeh-Parsi
Ahmad Afsari
Mehrdad Mohammadi
Publication date: 28-11-2021
Publisher: Springer Paris
Published in: International Journal of Material Forming / Issue 6/2021
Print ISSN: 1960-6206
Electronic ISSN: 1960-6214
DOI: https://doi.org/10.1007/s12289-021-01627-7

Springer Professional

Abstract

Please log in to get access to your license.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Other articles of this Issue 6/2021

A reduced single-pattern model for the numerical simulation of multi-pattern metal forming

Stamped part classification and automatic dieface design

Closed-loop control of product geometry by using an artificial neural network in incremental sheet forming with active medium

Fused filament fabrication printing process of polymers highly filled with metallic powder: a significant influence of the nozzle radiation on the substrate temperature

Numerical and experimental response of FSSW of AA5052-H32/epoxy/AA5052-H32 sandwich sheets with varying core properties

Consequences of large strain anisotropic work-hardening in cold forging

Premium Partners