Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Abstract
Applying one-step simulation to blank design in sheet metal forming was investigated. The authors have put forward and fullled the idea
that blank design should combine with the material properties and other industrial art conditions. The blank design for various depths of
square box was also completed. The results that were compared to those obtained by DYNAFORM showed that the blanks designed through
one-step simulation method are reasonable. The study of an industrial example also indicates that the one-step simulation method can be
used in large size auto-panel blank design. # 2002 Elsevier Science B.V. All rights reserved.
Keywords: Sheet metal forming; One-step simulation; Blank design
1. Introduction
There are numerous factors that inuence sheet metal
forming, such as the shape of the die, the properties of
the material, the shape of the blank, the boundary conditions,
the friction and the lubrication conditions between the
die and the blank, and so on. In the design of industrial
art for a metal forming process, one must consider them all
together. The blank shape and size is a very important factor.
Not only will it directly inuence the cost and the efciency
of the material, but also a reasonable design is likely to
improve the state of the part's strain and stress, increase the
limiting drawing ratio, make a smooth transition in the
thickness direction, and produce better quality products.
In addition, during auto-panel forming, the designing of
the blank shape is inuential in whether or not a part can be
produced.
Currently the main ways to design a blank are a geometric
modelling method [1], a calculation method based on slipling eld theory [2], or reliance on experience. Up to now a
general method to design all kinds of blank shape has not
been proposed. The existing method do not consider the
properties of the material and the boundary conditions to the
fullest extent, so that the blank shape that is obtained using
these methods is very approximate. The authors consider
that a perfect blank shape design must meet the following:
*
Corresponding author.
E-mail address: wangye@public2.sta.net.cn (Y. Wang).
0924-0136/02/$ see front matter # 2002 Elsevier Science B.V. All rights reserved.
PII: S 0 9 2 4 - 0 1 3 6 ( 0 1 ) 0 1 1 9 7 - 9
112
FEA method, one can locate the initial place P0 of the part's
node P at the initial blank C0 under a certain boundary
condition (Fig. 1). By comparing the node location between
the blank and the part, the distribution of the stress, strain
and the thickness in the part can be obtained.
From the above analysis, it is known that with the one-step
method the location of the discrete part's node at the blank
can be obtained. The nodes at the outline of the part
contribute to be the outline of the blank.
3. An example
3.1. The design of a square box blank
Using the die set shown in Fig. 2, the stroke is set to three
values (10, 20, 30 mm) and the shape of the workpiece is
determined. It is assumed that the workpiece's anges are all
5 mm and that the material is killed steel.
113
Fig. 6. The mesh of the square box deformation obtained from DYNAFORM.
114
4. Conclusions
This paper studied the application of the one-step method
to the blank design of sheet metal forming. For different
depth square box drawing, we compared the result from
the one-step method was compared with the result from
DYNAFORM software, the comparison showing that the
design is reasonable. The study on the Transit car backwheel hubcap also showed that it is possible to apply other
industrial art conditions to one-step method design. Thus, in
the opinion of the authors, the one-step method is a new
method to design blank of sheet metal forming and it will
take a place in the foreground of the blank design eld.
Fig. 9. The influence of the blank size of the setting of the draw-bead.
Acknowledgements
The work reported in this paper is supported by the Ford
China R&D project.
References
50
60
70
80
100
120
140
160
50
60
70
80
100
120
140
160