A Method for Simultaneous Optimization of Blank Shape and Forming Tool Geometry in Sheet Metal Forming Simulations

This paper presents a numerical method for simultaneous optimization of blank shape and forming tool geometry in three-dimensional sheet metal operations. The proposed iterative procedure enables the manufacturing products with fitting within specific tolerances (surface edge deviations less than 0.5 or 1.0 mm, respectively) that prescribe maximum allowable deviation between simulated desired geometry. Moreover, product is affected by an additional trimming phase after process. influences thinning, geometry, springback are considered throughout It demonstrated effectively optimizes seven iterations without unexpected convergence oscillations. Finally, thus developed experimentally validated on automobile elaborated design which prone to large amounts owning complex-phase advanced high strength steel material selection.