A 3D forming tool optimisation method considering springback and thinning compensation

Mole, Nikolaj; Cafuta, Gašper; Štok, Boris

doi:10.1016/j.jmatprotec.2014.03.017

Cited by 22 publications

(9 citation statements)

References 21 publications

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“…In this paper, we present a numerical method for the compensation of springback, thinning, and blank edge geometry which results in the simultaneous optimization of the blank shape and forming tool geometry. Based on our previous works, the proposed iterative procedure is developed by integrating the springback (and thinning) compensation algorithm [35,36] and the blank edge geometry correction algorithm [52] into one unified algorithm. To the best of the authors' knowledge, no study has yet comprehensively considered all these phenomena; this thus represents the main novelty of this paper.…”

Section: Discussionmentioning

confidence: 99%

“…Consequently, when dealing with 3D springback compensation, an appropriate correspondence between the product and the tool topologies must be established. In our previous works [35,36], this was achieved through improved normal description-surface description is improved to achieve C 1 continuity when a rectangular surface mesh is used. Moreover, besides springback compensation, the product's wall thickness is also optimized by taking into account that the inner and the outer side of the product interact with the adjusted tool (see also Bici et al [37]).…”

Section: State Of the Artmentioning

confidence: 99%

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A Method for Simultaneous Optimization of Blank Shape and Forming Tool Geometry in Sheet Metal Forming Simulations

Starman

Cafuta²,

Mole

2021

Metals

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This paper presents a numerical method for simultaneous optimization of blank shape and forming tool geometry in three-dimensional sheet metal forming operations. The proposed iterative procedure enables the manufacturing of sheet metal products with geometry fitting within specific tolerances (surface and edge deviations less than 0.5 or 1.0 mm, respectively) that prescribe the maximum allowable deviation between the simulated and desired geometry. Moreover, the edge geometry of the product is affected by the shape of the blank and by an additional trimming phase after the forming process. The influences of sheet metal thinning, edge geometry, and springback after forming and trimming are considered throughout the blank and tool optimization process. It is demonstrated that the procedure effectively optimizes the tool and blank shape within seven iterations without unexpected convergence oscillations. Finally, the procedure thus developed is experimentally validated on an automobile product with elaborated design and geometry which prone to large springback amounts owning to complex-phase advanced high strength steel material selection.

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Section: Discussionmentioning

confidence: 99%

Section: State Of the Artmentioning

confidence: 99%

A Method for Simultaneous Optimization of Blank Shape and Forming Tool Geometry in Sheet Metal Forming Simulations

Starman

Cafuta²,

Mole

2021

Metals

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“…In this section, we propose a new method of compensating for the injection moulded part warpage that aims to overcome the challenges mentioned above. The basis of the method is the Enhanced Displacement Adjustment (E-DA) method, developed by Cafuta and Mole [3,22,23,30] for use in sheet metal forming. Similar to injection moulding, where distortion of the shape manifests as warpage, the geometric accuracy in metal forming is hampered by springback and the thinning of the formed sheet metal part.…”

Section: Mould Cavity Geometry Correction Methodsmentioning

confidence: 99%

Correction of mould cavity geometry for warpage compensation

Kastelic

Starman²,

Cafuta³

et al. 2022

Int J Adv Manuf Technol

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Warpage is one of the most challenging defects occurring in plastic injection moulded parts. Various approaches to overcome this issue have been proposed in the literature, but they all provide only partial solutions to the problem. This paper proposes a new method for the compensation and minimisation of warpage. The method is based on Mould Cavity (MC) correction. In contrast to other similar methods, here the MC correction is accomplished through a direct comparison of the local deviations of the warped part's geometry to the desired geometry of the part. Modifying the MC shape accordingly yields parts with a lower shape discrepancy from the desired geometry compared to the nonadjusted shape. The key novelty of the paper is the development of software that iteratively adjusts the MC shape to minimise local deviations. In every iteration, the warped part is compared to the desired geometry and the MC geometry is adjusted accordingly. A curved thin-walled plate part case study demonstrates the method's capabilities. We show that the maximum warpage value of 0.005 mm (0.7% of the initial maximum warpage) was reached after three iterations of MC geometry correction and remained stable afterwards.

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“…For virtual fit analysis done previously, the deviation analysis tool in CATIA V5R21™ (Dassault Systemes, Velizy, FR) was frequently applied 9,11 in ergonomics design. Also, it is widely applied in product design optimisation 26 , additive manufacturing (AM) artifacts, and accuracy comparison 27 .…”

Section: Related Workmentioning

confidence: 99%

An earphone fit deviation analysis algorithm

Yan

Liu

Wang

2023

Sci Rep

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This study provides an accurate method for evaluating the fit of earphones, which could be used for establishing a linkage between interference/gap values with human perception. Seven commercial CAD software tools stood out and were explored for the analysis of the deviation between earphone and ear. However, the current deviation analysis method remains to be improved for earphone fit evaluation due to excessive points in the calculation (Geomagic Wrap and Siemens NX), lack of value on interference (Geomagic Control X), computation boundary required (Rapidform XOR/Redesign), repetitive computation with same points and inclined calculation line segment or even invalid calculation (Solidworks, Creo). Therefore, an accurate deviation analysis algorithm was promoted, which calculated the deviation between earphone and ear exactly and classified the interference set and gap set precisely. There are five main procedures of this algorithm, which are point cloud model pre-processing, the generation of distance vectors, the discrimination of interference set and gap set, the discrimination of validity, and statistical analysis and visualization. Furthermore, the usability and validity of the deviation analysis algorithm were verified through statistical analysis and comparing visual effects based on the earphone-wearing experiment. It is certified that the deviation analysis algorithm is appropriate for earphone fit evaluation and the eight indexes of this algorithm were proved to be related to subjective comfort scores. It is meaningful for ear-worn product fit analysis, design, and development phases.

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A 3D forming tool optimisation method considering springback and thinning compensation

Cited by 22 publications

References 21 publications

A Method for Simultaneous Optimization of Blank Shape and Forming Tool Geometry in Sheet Metal Forming Simulations

A Method for Simultaneous Optimization of Blank Shape and Forming Tool Geometry in Sheet Metal Forming Simulations

Correction of mould cavity geometry for warpage compensation

An earphone fit deviation analysis algorithm

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