The Stamping Process Design And Simulation Of Small Parts

In recent years, with the development and the application of computers and the maturity of finite element method, the numerical simulation of sheet metal forming has become a great powerful tools in stamping industry. This technology allows designers to foresee possible forming problems in the production preparation period,such as wrinkling,fracture,determine the needed forming process and technical parameters, and to optimize the mold designing. Every simulation is the same to a mold testing process, so mature simulation technology could not only reduce the times of mold testing, in certain conditions can also make the mould and process designing be qualified at one time, avoid repairing mold, thus we can greatly shorten the cycle of the new product development , reduce the development costs, improve the quality of the products and the market competitiveness .Combined with the actual need in production , this paper make numerical simulation work on the typical stamping parts, forecast and validation stamping results, solve the quality problems in the stamping process. To get 3-D mold by CATIA, and import these molds to DYNAFORM by standard exchange format"igs", do simulation works according to the actual conditions of industrial application simulated. Discussing the wrinkling,fracture,springback often appeared in stamping. The main content as follows:1. V-shaped parts bending process simulation In sheet metal forming, springback is the key factors should be considered in the mold design, because the final shape depends on the part's springback after forming. Choose four kinds of materials for 10,Q255,Q235,and 40 steel,the sheet thickness is 1.4 mm, bending radius is 3mm, bending angle is 90°,first of all, according to the relative bending radius r/t and bending angle a to find reference books and get the four kinds material's theory springback AngleΔa, after that we should simulate these bending parts by the DYNAFORM simulation software, and calculate their corresponding springback value, then compare the results with their theory springback values, after that we can verify the reliability of the simulation software DYNAFORM.2. Cylindrical parts deep drawing process analysis we should simulate AL and 08AL two kinds of material cylindrical parts, and get their limit deep drawing coefficient, after that we contrast the result with their own theory limit deep drawing coefficient .3. Low box parts with flange deep drawing process We should consider the following problems especially when drawing: The deformation area is very big, so the material near the flange is very easy to become wrinkle, and the punch round corner area is more and more thin because of the strong drawing, even ripping, causing deep drawing failure. So it is necessary to analysis the deep drawing deformation characteristics, find out the cause why the wrinkle,cracking occur, so as to guide the process and die design, in order to improve the quality of drawing parts. Use DYNAFORM software simulate the deep drawing process can conveniently and rapidly meet the requirement of analysis.4. The hydraulic deep drawing process analysis First we simulate the stepped-weir cylindrical parts with method of the soft die hydraulic deep drawing,then adopt the traditional deep drawing method to complete the forming process, after that compare their FLD diagrams and thickness distribution diagrams. When compare their thickness distribution diagrams, we can select a certain number of points at the same position in each diagram, and measure the thickness of each point, then calculate the average thickness and do the contrast.