Design optimization of hot stamping tooling produced by additive manufacturing

Chantzis, Dimitrios; Tracy, Michaela; Liu, Heli; Politis, Denis J.; Fu, Ming; Wang, Liliang

doi:10.1016/j.addma.2023.103728

Cited by 1 publication

(1 citation statement)

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“…However, topology optimization for metal forming is less focused than other manufacturing approaches. In stamping, for example, tremendous efforts were put toward optimizing the internal structure of the stamping die [45,46], and the die's light weight is significant for saving energy and green manufacturing. However, the mechanical performance of the sheet metal workpiece raises more interest for the end user, since the mechanical properties determine the load-bearing capacity during the utilization of the stamped sheet metal.…”

Section: Introductionmentioning

confidence: 99%

Topology Optimization Method of Stamping Structures Based on the Directional Density Field

Yuan,

Geng,

Wang

et al. 2024

Materials

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The stamping process produces thin-walled structures that, in general, have uniform wall thickness and no enclosed cavity. However, it is difficult to satisfy the above geometric requirements with the current density-based topology optimization method, since configuring the related geometric constraints is challenging. In order to solve this problem, a topology optimization method for stamping structures based on a directional density field is proposed. Specifically, the directional density field is developed to enable the adding and removing of materials only along the stamping direction, so as to avoid internal voids and concave features. The geometric control for uniform wall thickness is realized by tuning the truncation threshold of the Heaviside projection that processes the directional density field into the 0–1 binary field. At the same time, a calibrated filter radius of the truncation thresholds will facilitate the drawing angle control of the stamping ribs. The effectiveness of the established method has been verified by a number of numerical case studies. Results show that the proposed method can perform topology optimization for stamping structures with tunable uniform thickness and drawing angle control of the ribs. No internal voids or undercuts appear in the results. The results also disclose that a constant truncation threshold increment does not guarantee uniform wall thickness, and varying the threshold increments through surface offset and polynomial fitting is necessary.

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Section: Introductionmentioning

confidence: 99%