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Structural topology optimization of a stamping die made from high-strength steel sheet metal based on load mapping

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Abstract

Even though high-strength steel is a favourable material because of its high strength and good formability, this material poses new challenges on the structure of stamping dies owing to potential damages of the die during production. Stamping dies are conventionally produced according to design manuals and standard manufacturing guidelines, where a high safety factor is specified to ensure that the stamping die is heavy and thick. A structural topology optimization method for a stamping die is presented in this study based on finite element simulations of the sheet metal stamping process. The finite element model of the stamping die is first established. Next, the boundary forces acting on the sheet metal are obtained from simulations and these forces are applied to the punch surface by means of load mapping during topology optimization. These forces are equivalent to the interaction between the blank and die. The objective function is to maximize the static stiffness under multi-conditions, which is defined by using the compromise programming approach. The analytic hierarchy process method is used to determine the weight ratio of the body stiffness in various load conditions and conduct topology optimization of the comprehensive objective function. The results show that the weight of the optimal punch is reduced while its performance is improved. More importantly, the reconstructed punch can be manufactured practically.

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Acknowledgements

This work is supported by the National Key Technology Research and Development Program of the Ministry of Science and Technology of China (Grant no.: 2015BAF01B01) and the strategic emerging industry of Hunan province and science technology research projects (2016GK4008). The authors also wish to extend their greatest appreciation to Shanghai Tractor & Internal Combustion Engine Co. Ltd. for providing the stamping die used in the case study.

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Authors and Affiliations

  1. State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha, 410082, People’s Republic of China

    Hangyan Wang, Hui Xie, Qiming Liu, Yunfei Shen, Pinjian Wang & Licheng Zhao

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  1. Hangyan Wang
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  2. Hui Xie
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  3. Qiming Liu
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  4. Yunfei Shen
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  5. Pinjian Wang
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  6. Licheng Zhao
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Correspondence to Hui Xie.

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Wang, H., Xie, H., Liu, Q. et al. Structural topology optimization of a stamping die made from high-strength steel sheet metal based on load mapping. Struct Multidisc Optim 58, 769–784 (2018). https://doi.org/10.1007/s00158-018-1899-1

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