In the automotive industry, manufacturing processes for metal sheet forming are of crucial importance in terms of production time both in product development and in mass production. The concept of sheet metal forming processes generally involves simple forgings (hot or cold) between the tools and short lead times are crucial for accurate evaluations of candidate manufacturing processes during the product development process. In the design of sheet metal forming processes, the manual die try-out of tools is a time-consuming, expensive, and inexact process. To achieve the expected quality, it should be aimed to quickly prepare the tool surfaces for sheet metal parts and reduce try-out times. The present work investigates the possibility to design forming tools of sheet steel alloys, with acceptable accuracy at short lead times and with minimal need for the costly die try-out by digital manufacturing system with numerical simulation analysis. This method allows spotting the geometry based on the thinning distribution of a simulation result. Analyse results of punch force, thinning, and shape deviation are compared with data from separate forming experiments performed at moderately elevated temperatures. According to thinning results, the numerical responses show promising agreement with experimental measurements. So, machining surfaces can be numerically defined, leading to a shorter try-out of tools by reducing manual grinding processes. (ORCID ID: 0000-0002-7703-4431)
Anahtar Kelimeler: Forming tool, Try-out, Simulation, Sheet metal, Digital manufacturing system, Die spotting
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