Numerical Simulation Of Stamping Forming Process For Sheet Metal And Mold Design

With the development of sheet forming technology, the productive efficiency isincreasing constantly. Some precision instruments, space equipment or transportation such asplans, automobiles, ships are closely related to sheet forming. The constant development ofmanufacturing industry lead to the increase of demand for forming products, and theproduction efficiency must be kept at a higher level. At the same time, many manufacturingfirms have high demands for forming quality. It has been a significant tendency due to therequirement of saving automobile weight, and the requirements of more types or cars, highersurface quality and higher strength.All these factors will make that the stamping parts musthave a higher strength, have more complex structure and better surface quality. In theproduction of some precision instruments, their accuracy depends on every part’s precision.So the precision of every part need to be kept at a high level. These reasons make a bigshock to the traditional mold manufacturing industry.In older days, to avoid stamping defects, many tests are indispensable, which heavilyrelies on the field engineer’s experiences. This problem makes the cycle of the productsdesign longer and the additional cost higher. The contradiction between traditionalmanufacturing and highly efficiency is becoming sharper. Now the technology of CAE solvethis problem to some extent.The computer aided engineering makes it possible to forecast the stress and strain ofevery element in the process of forming. At present, there are many kinds of software tostamping FEM simulation,which can be used to computer simulation and optimum design.CAE software has become an essential tool for engineer. Software such as Autoform,Dynaform, PAM are more frequently used. Compared to other software, Autofrom is moreeffective, the mesh dividing is fully automated. Its biggest characteristic is easy to operateand it’s mainly used for cold stamping. It’s default unit type is membrane units. Relative toother software Autoform in recent years has realized in choosing the unit type frommembrane element and shell element which will ensure that the calculation is effective andaccurate enough. In this paper first, we use Autoform for one step forming analysis to unfoldthe blank. After the process analysis, we get the stamping order, the whole processsimulation will be created. According to the results, defects such as the wrinkling and cracking don’t appear, the surface quality of the parts meet the requirements, The mainlyproblem we deal with to improve the process is the springback, Through the orthogonalexperiment, we can get how The Uankholder force and lubrication condition effect the result，by increasing process step or using springback compensation the result will be better.The finite element simulation technology can shorten the mould manufacturing cycle，and the development of the progressive die technology greatly improved the machiningefficiency. Progressive die’s appearing is the results of production automation and highproductivity demands for, and this technology is developing gradually on the basis of thetraditional mould. Progressive die can complete all punching procedures on a set of mouldfor high speed production, even no body besides. The die is high efficiency, high precisionand long life. In this paper, the progressive die design based on UG PDW module areintroduced in detail, with large amount of professionals design experience included, themathematical model has been carried out through parts from the read products, processdesign, layout design and die design, standard parts design, at the end we will get theassembly drawing, PDW module provides designers with clear design ideas, which greatlyimprove the design efficiency and make it easier to modify, in this paper the design processwill be expounded in detail.