• Title/Summary/Keyword: Blank Design

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Development of Stamping Process Optimization System: Integration of Optimal Blank Design and Optimal Nesting (스템핑 공정 최적화 시스템의 개발 : 최적블랭크 설계와 최적배치의 일체화)

  • 심현보;이상헌;박종규;김흥업
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2003.05a
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    • pp.283-287
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    • 2003
  • In recent years, design of an optimal blank shape is very important for sheet metal forming process in the automobile industry because the raw material cost rate is significant part in the automobile industry. With the design of an optimal blank shape, the engineer can protect a blank from an excessive holding force to improve the quality and reduce the ratio of material scrap. Therefore design of an optimal blank shape is inevitable in sheet metal forming process. However, if it causes a complicated shape of blank, it may be difficult to do the blank layout optimally. In this study, we developed software of optimal blank layout connected with the software of optimal blank shape design which was created in the past by the present authors. And by using these softwares, we would like to present the method in order to get optimal utilization ratio easily and precisely within short time for the sequence of works from design to blank layout.

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Blank Design in Sheet Metal forming Process Using the Rollback Method (롤백방법을 이용한 박판금속성형공정에서의 블랭크 설계)

  • 김종엽;김낙수;허만성
    • Transactions of Materials Processing
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    • v.8 no.5
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    • pp.454-464
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    • 1999
  • A new blank design method is proposed to predict the optimum initial blank shape in the sheet metal forming process. The rollback method for blank shape design takes the difference between the deformed blank contour and the target contour shape into account. the minimization object function R is proposed. Based on the method, a computer program composed of blank design module, FE-analysis module and mesh generation module is developed. The rollback method is applied to square cup, reentrant cross section, L-shaped cup drawing process with the flange of uniform size around its periphery to confirm its validity. The optimum initial blank shape is obtained from an arbitrary blank shape after several modifications. Good agreements are recognized between the numerical results and the published experimental results for initial blank shape and thickness strain distribution. It is concluded that the rollback method is an effective and convenient method for an optimum blank shape design.

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Optimum Blank Design of Automobile Sub-Frame (우물정(井)자형 Sub-frame의 블랭크 설계)

  • Kim, Jong-Yop;Kim, Nak-Soo;Heo, Man-Seong
    • Transactions of Materials Processing
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    • v.7 no.3
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    • pp.260-273
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    • 1998
  • A new blank design method is proposed to predict the optimum initial blank shape in the sheet metal forming process. The rollback method for blank shape design takes the difference between final deformed shaped and target contour shape into account. Based on the method a computer program composed of blank design module FE-analysis program and mesh generation module is developed. The rollback method is applied to square cup drawing process with the flange of unifiorm size around its periphery to confirm its validity. The optimum initial blank shape is obtained from an arbitrary square blank after three modification. Good agreements are recognized between the numerical results and the published results for initial blank shape and thickness strain distribution. The optimum blank shape for two parts of automobile sub-frame is designed, The thickness distribution and the level of punch load is improved. Also the method is applied to design the weld line in the tailor-welded blank. It is concluded that the rollback method is an effective and convenient method for an optimum blank shape design.

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Optimum Blank Design of Automobile Sub-Frame (우물정자형 Sub-frame의 블랭크 설계)

  • 김종엽;김낙수;허만성
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 1998.03a
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    • pp.185-195
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    • 1998
  • A new blank design method is proposed to predict the optimum initial blank shape in the sheet metal forming process. The rollback method for blank shape design takes the difference between final deformed shape and target contour shape into account. Based on the method, a computer program composed of blank design module, FE-analysis program and mesh generation module is developed. The rollback method is applied to square cup drawing process with the flange of unifiorm size around its periphery to confirm its validity. The optimum initial blank shape is obtained from an arbitrary square blank after three modifications. Good agreements are recognized between the numerical results and the published results for initial blank shape and thickness strain distribution. The optimum blank shape for two parts of automobile sub-frame is designed. The thickness distribution and the level of punch load is improved. Also, the method is applied to design the weld line in the tailor-welded blank. It is concluded that the rollback method is an effective and convenient method for an optimum blank shape design.

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A Study on the Intial Blank Design Using Ideal Forming Theory (이상적 변형이론을 이용한 박판 초기형상 설계에 관한 연구)

  • 박상후;윤정환;양동열;김용환;이장희
    • Transactions of the Korean Society of Automotive Engineers
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    • v.5 no.4
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    • pp.207-218
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    • 1997
  • A new blank design method is introduced to predict the blank shape and the strain distribution in the sheet metal forming process. This method deals with only one step from the final shape to the initial blank using the ideal forming theory. Based on this theory, a three-dimensional membrane finite element code has been developed to design an initial blank in the sheet metal forming process. In this paper, the designs of initial blanks for forming a cylindrical cup, a rectangular cup, and a front fender are presented as examples. Also, it compares the two shapes, the target shape with the shape which is deformed from the initial blank using the FEM analysis code. The results illustrate the information that this direct design code is useful in the preliminary design state.

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Development of Stamping Process Optimization System through the Integration of Blank Design and Nesting (블랭크 설계와 배치의 일체화를 통한 스탬핑 공정 최적화 시스템의 개발)

  • 심현보;박종규
    • Transactions of Materials Processing
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    • v.12 no.7
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    • pp.615-622
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    • 2003
  • In the automobile industry, the design of optimal blank shape becomes a significant part of the stamping. It provides many evident advantages, sush as enhancement of formability, reduction of material cost and product development period. However, the nesting process, required for the optimal usage of materials in the blanking becomes more complicated as the blank shape becomes complicated, like most optimal blank shape. In this study, stamping process optimization system for the optimal usage of material has been developed through the integration of optimal blank design and optimal nesting. For optimal blank design, a radius vector method, the modified version of the initial nodal velocity method, the past work of the present author, have been proposed. Both the optimal blank design and optimal nesting programs have been developed under the GUI environment for the convenience of engineers. The efficiency of the optimization system has been verified with some chosen problems.

Optimization of blank geometry for the stamping process of B-pillar using design of experiments (실험 계획법을 사용한 B-Pillar 성형공정에서 블랭크 형상 최적화)

  • Youn, Hyung-Won;Choi, Yong-seok;Lee, Chang-Whan
    • Design & Manufacturing
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    • v.15 no.2
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    • pp.17-22
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    • 2021
  • The shape of the blank greatly affects the formability and quality of the product after the stamping process. In this study, the geometry of the B-Pillar blank in the stamping process was optimized using design of experiments. The geometry of the blank for the B-pillar was simplified with the two length values and two radius values. The effects of design variables were studied through the Design of experiments. The stamping process of the B-pillar was predicted with the Finite Element Analysis (FEA). The optimized blank geometry was obtained. It results in the reduced maximum equivalent plastic strain. The local necking and the wrinkling did not occurred with the optimized blank geometry.

An Application of Optimal Blank Design by Sensitivity Analysis to Stampings of General Shaped parts (민감도를 이용한 최적블랭크 설계법의 CAD 형식으로 표현된 금형에의 적용)

  • 손기찬
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 1999.03a
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    • pp.45-48
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    • 1999
  • The optimal blank design method by sensitivity analysis has been applied to the formings of oil-pan, tailored blank and front panel have been chosen as the examples. Die shape is prepared by a commercial CAD system. Excellent results has been obtained between the numerical results and the target contour shapes. Through the investigation, the proposed systematic method of optimal blank design is found to be effective in the practical forming processes.

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An Application of Optimal Blank Design by the Sensitivity Analysis to the Stampings of General Shaped Parts (민감도법을 이용한 최적블랭크 설계법의 일반적인 모양의 금형에의 적용)

  • 심현보;손기찬;황현태
    • Transactions of Materials Processing
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    • v.9 no.3
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    • pp.226-232
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    • 2000
  • The optimal blank design method by sensitivity analysis has been applied to the formings of oil-pan, tailored blank and front panel as the examples. Die geometry is prepared by a commercial CAD system. Excellent results has been obtained between the numerical results and the target contour shapes. Through the investigation, the proposed systematic method of optimal blank design is found to be effective in the practical forming processes.

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Optimal Blank Design for Sheet Metal Stamping (박판성형공정의 블랭크 최적설계)

  • 김용환
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2000.04a
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    • pp.141-145
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    • 2000
  • A systematic method to find the optimal blank shape for sheet forming is proposed by coupling the numerical simulation technique. A weighted parameter was introduced in order to simplify the multi-variable optimization problem to a single-variable problem. The proposed method has been applied to the blank design of drawing processes to obtain the near-net shape within the required error bound after forming, Excellent results have been obtained between the numerical results and the target contour shapes. Through the investigation the proposed systematic method for optimal blank design is found to be effective in the practical forming processes

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