Stress-based compensation of geometrical deviations in metal forming

To achieve a suitable designs of the tools for metal forming processes, numerous iterations of modifications are often necessary. To obtain a product within strict tolerances, the tool geometry has to be adjusted finely. This revision procedure is often user-dependent and based on practical knowledge. It usually consists of numerical simulations, subsequent verification tests and redesign steps, which result in high costs and time exposure. According to these issues, the process of redesign the tool geometry can be improved regarding efficiency. In this work, a stress-based compensation method of geometrical deviations is proposed. This compensation method is based on a two-step elastic FEM analysis: firstly, a stress distribution, which compensate geometric deviations, is determined. Secondly, based on the resultant stress distribution, a new geometry of the forming tool is derived. Numerical and experimental tensile and bend tests are performed to verify the new compensation method. In addition, a stretch bending test is also simulated. This proposed method can be used in a context of a holistic process and it can lead to a more time and cost-effective way of redesigning forming tools.     «

To achieve a suitable designs of the tools for metal forming processes, numerous iterations of modifications are often necessary. To obtain a product within strict tolerances, the tool geometry has to be adjusted finely. This revision procedure is often user-dependent and based on practical knowledge. It usually consists of numerical simulations, subsequent verification tests and redesign steps, which result in high costs and time exposure. According to these issues, the process of redesign the...     »