Abstract
Although today’s deep drawing tools are thoroughly designed and calculated by means of computer-aided design (CAD), finite element (FE) simulation and computer-aided manufacturing (CAM), the sequence of operations to put a tool into production still encompasses manual and irreproducible labor. In particular, the die spotting is empirical and is almost entirely dependent on the toolmaker’s experience. This fine-tuning of the drawing tool consumes a large amount of time. In minimizing manual die spotting, a large potential to decrease time and costs exists. This article presents error compensation methods to create deep drawing tools, which require less manual die spotting in order to produce sound quality stampings. In FE simulations of deep drawing operations, it is general practice to assume rigid tool and press properties. The fact that die and punch design are based on these simplifications might be one of the main causes that empirical die spotting is still imperative. Therefore, the authors developed a methodology to compensate the tool face for effects of elastic press and tool deformations, which occur under applied process load. The authors demonstrate the static compensation with two examples. The first shows the static compensation for ram tilting caused by an unbalanced load, which can originate from asymmetric part design and/or eccentric mounted tools. The second example describes the compensation for elastic die deformation caused by local and global deflections. In either case, the compensated die face, under applied process load, deformed into the desired die face. This research work shows the potential and limits of a static compensation for effects of elastic tool and press deformations on the final shape of the stamping.
Similar content being viewed by others
References
Roll K (2008) Simulation of sheet metal forming—necessary developments in the future, 7. LS-DYNA Anwenderforum. pp A-I-59–A-I-68
Stalmann A, Weigert P (2009) Werkzeugtechnik der Zukunft—Anforderungen und Möglichkeiten, EFB Servopressen und Werkzeugsysteme zur Blechverarbeitung. pp 93–106
Großmann K, Wiemer H, Hardtmann A, Penter L (2007) Faster to sound parts by advanced forming process simulation—advanced forming process model including the elastic effects of the forming press and tool, Steel Research Int., 78. pp 825–830
Clarke M (2008) Sheet metal forming simulation and real world tooling. 10th international LS-DYNA® user’s conference. pp 2-27–2-34
Helduser S, Lohse H, Behrens B-A, Marthiens O, Matthias T (2009) Optimisation of the drive control in hydraulic deep drawing presses by using a holistic simulation. The 11th Scandinavian international conference on fluid power, SICFP’09, proceedings, Linköping, Sweden, 2009
Brecher C, Schapp L, Paepenmüller F (2006) Gekoppelte Simulation von Presse und Massivumformprozess, Werkstattstechnik online Jahrgang 96. Springer-VDI-Verlag GmbH & Co. KG, Düsseldorf
Ebert A, Awiszus B (2006) Automatische Kompensation der berechneten elastischen Werkzeugdeformation von Schmiedewerkzeugen Schmiede-Journal, 03/06, pp 36/37
Meinhardt J (2009) Simulation- und Messdatenbasierte Rückfederungskompensation. EFB Servopressen und Werkzeugsysteme zur Blechverarbeitung. pp 211–219
Breadel M, Palaniswamy H, Golle M, Hoffmann H, Altan T, Griesbach B (2008) Investigation of die try-out using programmable multipoint cushion system for stamping large automotive body panels. ITCP, proceedings, Gyeongju, Korea, 2008
Haufe A (2008) Sheet metal forming simulation with elastic tools in Ls-Dyna, Numisheet. pp 743–748
Acknowledgments
The authors would like to thank the German Research Foundation (DFG) for their financial support. This work has been carried out during the Priority Program SPP1180 “Prediction and Manipulation of Interactions between Structure and Process”.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Großmann, K., Wiemer, H., Hardtmann, A. et al. Static compensation for elastic tool and press deformations during deep drawing. Prod. Eng. Res. Devel. 4, 157–164 (2010). https://doi.org/10.1007/s11740-010-0216-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11740-010-0216-7