Study On Optimization Of Blank Corner Dimensions Of Shallow Square Boxes Without Flanges

During the forming process of square boxes ,blank shape and size are also important factors,in addition to material performance, forming features, mold state and lubricating conditions etc. For the blanks of larger corner dimensions of shallow square boxes without flanges, it is required drawing an outline of blanks in order to unknit the end face of the blank after once forming. Currently, during the process of producing the type parts in majority factories, the calculation size is launched according to the empirical formula. Based on the result, we can draw the outline of blanks. Using this method, the blank size is near to the ideal outline. But the precision of product in the actual production is unsatisfactorily. So we must find a logical calculation method and design model for shallow square boxes in order to guarantee the forming quality and improve the economic performance.With the development of computer technical and FEM theory, FEM have made a commonly application in the forming analyse of blank sheet. The main advantage of this kind of method is that it can be in consideration of all of forming factors, such as geometry shapes, physics and mechanics factors. So it can be more accurately simulation and analysis. Firstly, in the paper, 3D models of mold and parts were built by using CAD software. Then it uses the DYNAFROM software to analyse the forming process of different height square box parts. Using the method, it analyzed the forming regulation of the blanks of larger corner dimensions of shallow square boxes without flanges for forming height. Aim at the the forming characteristics of the district of shallow square box blank circle cape, it optimize the blank outside size and make a correction for outspread formula of circle corner size. The formula was applied to other shallow drawing parts and outside convexly turning sides piece and it was verified successful by the result of FEM simulation. At the same time, it improves the analysis efficiency and reduced the calculation time by using the adaptive remeshing function. Finally, the formula was applied to practical production. According to the results comparison of practical and simulation, the formula is logical.By the study on optimization of blank corner dimensions of shallow square boxes without flanges, it combines the forming theory of boxes and FEM simulation technical. In this way, it achieved the scheduled goals. The research results can guide the production of other similar parts and will play an important role in interrelated fields study.