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

Starman, Bojan; Cafuta, Gašper; Mole, Nikolaj

doi:10.3390/met11040544

Cited by 15 publications

(11 citation statements)

References 55 publications

(64 reference statements)

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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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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

Self Cite

View full text Add to dashboard Cite

show abstract

Section: Introductionmentioning

confidence: 99%

“…The FEM simulations of metal-processing technologies are often implemented in industrial practice prior to the part production [ 19 , 20 , 21 , 22 ]. However, for process optimisation, they are often not effective enough due to long computational time, modelling complexity, and insufficient accuracy of the simulated part [ 18 , 19 ]. Although the majority of the simulations of sheet metal incremental forming apply shell elements, long computational times are in several cases referred to as a fundamental problem.…”

Section: Introductionmentioning

confidence: 99%

“…The possibilities of the computational efficiency improvement in the FE simulation of ISF processes using a selective element fission method are presented in [ 19 ]. The computational performance was upgraded up to 74% by dividing the toolpath into a number of segments and meshing the FE model with elements of different size in accordance with the predefined split toolpath segments and deformation regions.…”

Section: Introductionmentioning

confidence: 99%

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Finite Element Simplifications and Simulation Reliability in Single Point Incremental Forming

et al. 2022

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Single point incremental forming (SPIF) is one of the most promising technologies for the manufacturing of sheet metal prototypes and parts in small quantities. Similar to other forming processes, the design of the SPIF process is a demanding task. Nowadays, the design process is usually performed using numerical simulations and virtual models. The modelling of the SPIF process faces several challenges, including extremely long computational times caused by long tool paths and the complexity of the problem. Path determination is also a demanding task. This paper presents a finite element (FE) analysis of an incrementally formed truncated pyramid compared to experimental validation. Focus was placed on a possible simplification of the FE process modelling and its impact on the reliability of the results obtained, especially on the geometric accuracy of the part and bottom pillowing effect. The FE modelling of SPIF process was performed with the software ABAQUS, while the experiment was performed on a conventional milling machine. Low-carbon steel DC04 was used. The results confirm that by implementing mass scaling and/or time scaling, the required calculation time can be significantly reduced without substantially affecting the pillowing accuracy. An innovative artificial neural network (ANN) approach was selected to find the optimal values of mesh size and mass scaling in term of minimal bottom pillowing error. However, care should be taken when increasing the element size, as it has a significant impact on the pillow effect at the bottom of the formed part. In the range of selected mass scaling and element size, the smallest geometrical error regarding the experimental part was obtained by mass scaling of 19.01 and tool velocity of 16.49 m/s at the mesh size of 1 × 1 mm. The obtained results enable significant reduction of the computational time and can be applied in the future for other incrementally formed shapes as well.

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“…The need to continually advance the modeling of processes and their limits is a recent trend in manufacturing engineering. Robust process design and parameterization can be effectively evaluated with appropriate models [3], which helps feed the demand for tighter product tolerances [4]. The inclusion of these models and the virtualization of the work area and workpiece allow the digitization of manufacturing in the era of new smart factories [5].…”

Section: Introductionmentioning

confidence: 99%

Three-Dimensional Finite Element Modelling of Sheet Metal Forming for the Manufacture of Pipe Components: Symmetry Considerations

Bhujangrao¹,

Veiga

Penalva³

et al. 2022

Symmetry

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The manufacture of parts by metal forming is a widespread technique in sectors such as oil and gas and automotives. It is therefore important to make a research effort to know the correct set of parameters that allow the manufacture of correct parts. This paper presents a process analysis by means of the finite element model. The use case presented in this paper is that of a 3-m diameter pipe component with a thickness of 22 mm. In this type of application, poor selection of process conditions can result in parts that are out of tolerance, both in dimensions and shape. A 3D finite element model is made, and the symmetry of the tube section generated in 2D is analysed. As a novelty, an analysis of the process correction as a function of the symmetrical deformation of the material in this case in the form of a pipe is carried out. The results show a correct fitting of the model and give guidelines for manufacturing.

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

Cited by 15 publications

References 55 publications

Correction of mould cavity geometry for warpage compensation

Correction of mould cavity geometry for warpage compensation

Finite Element Simplifications and Simulation Reliability in Single Point Incremental Forming

Three-Dimensional Finite Element Modelling of Sheet Metal Forming for the Manufacture of Pipe Components: Symmetry Considerations

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