Finite element analysis and topology optimization of a 12000KN fine blanking press frame

Fine blanking press frame is one of the core components of the fine blanking press. Good performance of the frame is of great importance to ensure blanking precision. Simultaneously, lightweight of the frame would decrease the total press weight, and reduce the consumption of manufacturing and transportation. In this paper, the topology optimization technology was used to optimize a 12000KN fine blanking press frame. Firstly, a finite element model was established to analyze the original 12000KN fine blanking press frame. The proper way of finite element modelling was determined by an experiment. Then, an optimization problem was formulated using Solid Isotropic Microstructures with Penalization (SIMP) method. After that, a testing topology optimization was conducted, whose result revealed some complex, non-manufacturable design features. To cope with these exposed issues and obtain a result with clearer configuration and better manufacturability, a two-stage optimization procedure was proposed, in which manufacturing constraints played an important role. Ultimately, an optimized CAD model for the frame was constructed, and finite element analysis showed that 13.66 % volume reduction was achieved while the performance slightly increased compared with the original frame.