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第0页共50页PROCESSSIMULATIONINSTAMPINGRECENTAPPLICATIONSFORPRODUCTANDPROCESSDESIGNABSTRACTPROCESSSIMULATIONFORPRODUCTANDPROCESSDESIGNISCURRENTLYBEINGPRACTICEDININDUSTRYHOWEVER,ANUMBEROFINPUTVARIABLESHAVEASIGNIFICANTEFFECTONTHEACCURACYANDRELIABILITYOFCOMPUTERPREDICTIONSASTUDYWASCONDUCTEDTOEVALUATETHECAPABILITYOFFESIMULATIONSFORPREDICTINGPARTCHARACTERISTICSANDPROCESSCONDITIONSINFORMINGCOMPLEXSHAPED,INDUSTRIALPARTSININDUSTRIALAPPLICATIONS,THEREARETWOOBJECTIVESFORCONDUCTINGFESIMULATIONSOFTHESTAMPINGPROCESS1TOOPTIMIZETHEPRODUCTDESIGNBYANALYZINGFORMABILITYATTHEPRODUCTDESIGNSTAGEAND2TOREDUCETHETRYOUTTIMEANDCOSTINPROCESSDESIGNBYPREDICTINGTHEDEFORMATIONPROCESSINADVANCEDURINGTHEDIEDESIGNSTAGEFOREACHOFTHESEOBJECTIVES,TWOKINDSOFFESIMULATIONSAREAPPLIEDPAMSTAMP,ANINCREMENTALDYNAMICEXPLICITFEMCODERELEASEDBYENGINEERINGSYSTEMSINTL,MATCHESTHESECONDOBJECTIVEWELLBECAUSEITCANDEALWITHMOSTOFTHEPRACTICALSTAMPINGPARAMETERSFAST_FORM3D,AONESTEPFEMCODERELEASEDBYFORMINGTECHNOLOGIES,MATCHESTHEFIRSTOBJECTIVEBECAUSEITONLYREQUIRESTHEPARTGEOMETRYANDNOTTHECOMPLEXPROCESSINFORMATIONINAPREVIOUSSTUDY,THESETWOFECODESWEREAPPLIEDTOCOMPLEXSHAPEDPARTSUSEDINMANUFACTURINGAUTOMOBILESANDCONSTRUCTIONMACHINERYTHEIRCAPABILITIESINPREDICTINGFORMABILITYISSUESINSTAMPINGWEREEVALUATEDTHISPAPERREVIEWSTHERESULTSOFTHISSTUDYANDSUMMARIZESTHERECOMMENDEDPROCEDURESFOROBTAININGACCURATEANDRELIABLERESULTSFROMFESIMULATIONSINANOTHERSTUDY,THEEFFECTOFCONTROLLINGTHEBLANKHOLDERFORCEBHFDURINGTHEDEEPDRAWINGOFHEMISPHERICAL,DOMEBOTTOMEDCUPSWASINVESTIGATEDTHESTANDARDAUTOMOTIVEALUMINUMKILLED,DRAWINGQUALITYAKDQSTEELWASUSEDASWELLASHIGHPERFORMANCEMATERIALSSUCHASHIGHSTRENGTHSTEEL,BAKEHARDSTEEL,ANDALUMINUM6111ITWASDETERMINEDTHATVARYINGTHEBHFASAFUNCTIONOFSTROKEIMPROVEDTHESTRAINDISTRIBUTIONSINTHEDOMEDCUPSKEYWORDSSTAMPINGPROCESSSTIMULATIONPROCESSDESIGN第1页共50页1INTRODUCTIONTHEDESIGNPROCESSOFCOMPLEXSHAPEDSHEETMETALSTAMPINGSSUCHASAUTOMOTIVEPANELS,CONSISTSOFMANYSTAGESOFDECISIONMAKINGANDISAVERYEXPENSIVEANDTIMECONSUMINGPROCESSCURRENTLYININDUSTRY,MANYENGINEERINGDECISIONSAREMADEBASEDONTHEKNOWLEDGEOFEXPERIENCEDPERSONNELANDTHESEDECISIONSARETYPICALLYVALIDATEDDURINGTHESOFTTOOLINGANDPROTOTYPINGSTAGEANDDURINGHARDDIETRYOUTSVERYOFTENTHESOFTANDHARDTOOLSMUSTBEREWORKEDOREVENREDESIGNEDANDREMANUFACTUREDTOPROVIDEPARTSWITHACCEPTABLELEVELSOFQUALITYTHEBESTCASESCENARIOWOULDCONSISTOFTHEPROCESSOUTLINEDINFIG1INTHISDESIGNPROCESS,THEEXPERIENCEDPRODUCTDESIGNERWOULDHAVEIMMEDIATEFEEDBACKUSINGASPECIALLYDESIGNSOFTWARECALLEDONESTEPFEMTOESTIMATETHEFORMABILITYOFTHEIRDESIGNTHISWOULDALLOWTHEPRODUCTDESIGNERTOMAKENECESSARYCHANGESUPFRONTASOPPOSEDTODOWNTHELINEAFTEREXPENSIVETOOLINGHASBEENMANUFACTUREDONESTEPFEMISPARTICULARLYSUITEDFORPRODUCTANALYSISSINCEITDOESNOTREQUIREBINDER,ADDENDUM,OREVENMOSTPROCESSCONDITIONSTYPICALLYTHISINFORMATIONISNOTAVAILABLEDURINGTHEPRODUCTDESIGNPHASEONESTEPFEMISALSOEASYTOUSEANDCOMPUTATIONALLYFAST,WHICHALLOWSTHEDESIGNERTOPLAY“WHATIF”WITHOUTMUCHTIMEINVESTMENTFIG1PROPOSEDDESIGNPROCESSFORSHEETMETALSTAMPINGSONCETHEPRODUCTHASBEENDESIGNEDANDVALIDATED,THEDEVELOPMENTPROJECTWOULDENTERTHE“TIMEZERO”PHASEANDBEPASSEDONTOTHEDIEDESIGNERTHEDIEDESIGNERWOULDVALIDATEHIS/HERDESIGNWITHANINCREMENTALFEMCODEANDMAKENECESSARYDESIGNCHANGESANDPERHAPSEVENOPTIMIZETHEPROCESSPARAMETERSTOENSURENOTJUSTMINIMUMACCEPTABILITYOFPARTQUALITY,BUTMAXIMUMACHIEVABLEQUALITYTHISINCREASESPRODUCTQUALITYBUTALSOINCREASEPROCESSROBUSTNESSINCREMENTALFEMISPARTICULARLYSUITEDFORDIEDESIGNANALYSISSINCEITDOESREQUIREBINDER,ADDENDUM,ANDPROCESSCONDITIONSWHICHAREEITHERKNOWNDURINGDIEDESIGNORDESIREDTOBEKNOWNTHEVALIDATEDDIEDESIGNWOULDTHENBEMANUFACTUREDDIRECTLYINTOTHEHARDPRODUCTIONTOOLINGANDBEVALIDATEDWITHPHYSICALTRYOUTSDURINGWHICHTHEPROTOTYPEPARTSWOULDBEMADETRYOUTTIMESHOULDBEDECREASEDDUETOTHEEARLIERNUMERICALVALIDATIONSREDESIGNANDREMANUFACTURINGOFTHETOOLINGDUETOUNFORESEENFORMINGPROBLEMSSHOULDBEATHINGOFTHEPASTTHEDECREASEINTRYOUTTIMEANDELIMINATIONOFREDESIGN/REMANUFACTURINGSHOULDMORETHANMAKEUPFORTHETIMEUSEDTONUMERICALLYVALIDATETHEPART,DIE,ANDPROCESS第2页共50页OPTIMIZATIONOFTHESTAMPINGPROCESSISALSOOFGREATIMPORTANCETOPRODUCERSOFSHEETSTAMPINGSBYMODESTLYINCREASINGONESINVESTMENTINPRESSES,EQUIPMENT,ANDTOOLINGUSEDINSHEETFORMING,ONEMAYINCREASEONESCONTROLOVERTHESTAMPINGPROCESSTREMENDOUSLYITHASBEENWELLDOCUMENTEDTHATBLANKHOLDERFORCEISONEOFTHEMOSTSENSITIVEPROCESSPARAMETERSINSHEETFORMINGANDTHEREFORECANBEUSEDTOPRECISELYCONTROLTHEDEFORMATIONPROCESSBYCONTROLLINGTHEBLANKHOLDERFORCEASAFUNCTIONOFPRESSSTROKEANDPOSITIONAROUNDTHEBINDERPERIPHERY,ONECANIMPROVETHESTRAINDISTRIBUTIONOFTHEPANELPROVIDINGINCREASEDPANELSTRENGTHANDSTIFFNESS,REDUCEDSPRINGBACKANDRESIDUALSTRESSES,INCREASEDPRODUCTQUALITYANDPROCESSROBUSTNESSANINEXPENSIVE,BUTINDUSTRIALQUALITYSYSTEMISCURRENTLYBEINGDEVELOPEDATTHEERC/NSMUSINGACOMBINATIONOFHYDRAULICSANDNITROGENANDISSHOWNINFIG2USINGBHFCONTROLCANALSOALLOWENGINEERSTODESIGNMOREAGGRESSIVEPANELSTOTAKEADVANTAGETHEINCREASEDFORMABILITYWINDOWPROVIDEDBYBHFCONTROLFIG2BLANKHOLDERFORCECONTROLSYSTEMANDTOOLINGBEINGDEVELOPEDATTHEERC/NSMLABSTHREESEPARATESTUDIESWEREUNDERTAKENTOSTUDYTHEVARIOUSSTAGESOFTHEDESIGNPROCESSTHENEXTSECTIONDESCRIBESASTUDYOFTHEPRODUCTDESIGNPHASEINWHICHTHEONESTEPFEMCODEFAST_FORM3DFORMINGTECHNOLOGIESWASVALIDATEDWITHALABORATORYANDINDUSTRIALPARTANDUSEDTOPREDICTOPTIMALBLANKSHAPESSECTION4SUMMARIZESASTUDYOFTHEDIEDESIGNSTAGEINWHICHANACTUALINDUSTRIALPANELWASUSEDTOVALIDATETHEINCREMENTALFEMCODEPAMSTAMPENGINEERINGSYSTEMSINTLSECTION5COVERSALABORATORYSTUDYOFTHEEFFECTOFBLANKHOLDERFORCECONTROLONTHESTRAINDISTRIBUTIONSINDEEPDRAWN,HEMISPHERICAL,DOMEBOTTOMEDCUPS2PRODUCTSIMULATIONAPPLICATIONSTHEOBJECTIVEOFTHISINVESTIGATIONWASTOVALIDATEFAST_FORM3D,TODETERMINEFAST_FORM3DSBLANKSHAPEPREDICTIONCAPABILITY,ANDTODETERMINEHOWONESTEPFEMCANBEIMPLEMENTEDINTOTHEPRODUCTDESIGNPROCESSFORMINGTECHNOLOGIESHASPROVIDEDTHEIRONESTEPFEMCODEFAST_FORM3DANDTRAININGTOTHEERC/NSMFORTHEPURPOSEOFBENCHMARKINGANDRESEARCHFAST_FORM3DDOESNOTSIMULATETHEDEFORMATIONHISTORYINSTEADITPROJECTSTHEFINALPARTGEOMETRYONTOAFLATPLANEORDEVELOPABLESURFACEANDREPOSITIONSTHENODESANDELEMENTSUNTILAMINIMUMENERGYSTATEISREACHEDTHISPROCESSISCOMPUTATIONALLYFASTERTHANINCREMENTALSIMULATIONSLIKEPAMSTAMP,BUTALSOMAKESMOREASSUMPTIONSFAST_FORM3DCANEVALUATEFORMABILITYANDESTIMATEOPTIMALBLANKGEOMETRIESANDISASTRONGTOOLFORPRODUCTDESIGNERSDUETOITSSPEEDANDEASEOFUSEPARTICULARLYDURINGTHESTAGEWHENTHEDIEGEOMETRYISNOTAVAILABLE第3页共50页INORDERTOVALIDATEFAST_FORM3D,WECOMPAREDITSBLANKSHAPEPREDICTIONWITHANALYTICALBLANKSHAPEPREDICTIONMETHODSTHEPARTGEOMETRYUSEDWASA5INDEEP12INBY15INRECTANGULARPANWITHA1INFLANGEASSHOWNINFIG3TABLE1LISTSTHEPROCESSCONDITIONSUSEDROMANOVSKISEMPIRICALBLANKSHAPEMETHODANDTHESLIPLINEFIELDMETHODWASUSEDTOPREDICTBLANKSHAPESFORTHISPARTWHICHARESHOWNINFIG4FIG3RECTANGULARPANGEOMETRYUSEDFORFAST_FORM3DVALIDATIONTABLE1PROCESSPARAMETERSUSEDFORFAST_FORM3DRECTANGULARPANVALIDATIONFIG4BLANKSHAPEDESIGNFORRECTANGULARPANSUSINGHANDCALCULATIONSAROMANOVSKISEMPIRICALMETHODBSLIPLINEFIELDANALYTICALMETHODFIG5ASHOWSTHEPREDICTEDBLANKGEOMETRIESFROMTHEROMANOVSKIMETHOD,SLIPLINEFIELDMETHOD,ANDFAST_FORM3DTHEBLANKSHAPESAGREEINTHECORNERAREA,BUTDIFFERGREATLYINTHESIDEREGIONSFIG5BCSHOWTHEDRAWINPATTERNAFTERTHEDRAWINGPROCESSOFTHERECTANGULARPANASSIMULATEDBYPAMSTAMPFOREACHOFTHEPREDICTEDBLANKSHAPESTHEDRAWINPATTERNSFORALLTHREERECTANGULARPANSMATCHEDINTHECORNERSREGIONSQUITEWELLTHESLIPLINEFIELDMETHOD,THOUGH,DIDNOTACHIEVETHEOBJECTIVE1INFLANGEINTHESIDEREGION,WHILETHEROMANOVSKIANDFAST_FORM3D第4页共50页METHODSACHIEVEDTHE1INFLANGEINTHESIDEREGIONSRELATIVELYWELLFURTHER,ONLYTHEFAST_FORM3DBLANKAGREESINTHECORNER/SIDETRANSITIONREGIONSMOREOVER,THEFAST_FORM3DBLANKHASABETTERSTRAINDISTRIBUTIONANDLOWERPEAKSTRAINTHANROMANOVSKIASCANBESEENINFIG6FIG5VARIOUSBLANKSHAPEPREDICTIONSANDPAMSTAMPSIMULATIONRESULTSFORTHERECTANGULARPANATHREEPREDICTEDBLANKSHAPESBDEFORMEDSLIPLINEFIELDBLANKCDEFORMEDROMANOVSKIBLANKDDEFORMEDFAST_FORM3DBLANKFIG6COMPARISONOFSTRAINDISTRIBUTIONOFVARIOUSBLANKSHAPESUSINGPAMSTAMPFORTHERECTANGULARPANADEFORMEDROMANOVSKIBLANKBDEFORMEDFAST_FORM3DBLANKTOCONTINUETHISVALIDATIONSTUDY,ANINDUSTRIALPARTFROMTHEKOMATSULTDWASCHOSENANDISSHOWNINFIG7AWEPREDICTEDANOPTIMALBLANKGEOMETRYWITHFAST_FORM3DANDCOMPAREDITWITHTHEEXPERIMENTALLYDEVELOPEDBLANKSHAPEASSHOWNINFIG7BASSEEN,THEBLANKSARESIMILARBUTHAVESOMEDIFFERENCESFIG7FAST_FORM3DSIMULATIONRESULTSFORINSTRUMENTCOVERVALIDATIONAFAST_FORM3DSFORMABILITYEVALUATIONBCOMPARISONOFPREDICTEDANDEXPERIMENTALBLANKGEOMETRIESNEXTWESIMULATEDTHESTAMPINGOFTHEFAST_FORM3DBLANKANDTHEEXPERIMENTALBLANKUSINGPAMSTAMPWECOMPAREDBOTHPREDICTEDGEOMETRIESTOTHENOMINALCADGEOMETRYFIG8ANDFOUNDTHATTHEFAST_FORM3DGEOMETRYWASMUCH第5页共50页MOREACCURATEANICEFEATUREOFFAST_FORM3DISTHATITCANSHOWA“FAILURE”CONTOURPLOTOFTHEPARTWITHRESPECTTOAFAILURELIMITCURVEWHICHISSHOWNINFIG7AINCONCLUSION,FAST_FORM3DWASSUCCESSFULATPREDICTINGOPTIMALBLANKSHAPESFORALABORATORYANDINDUSTRIALPARTSTHISINDICATESTHATFAST_FORM3DCANBESUCCESSFULLYUSEDTOASSESSFORMABILITYISSUESOFPRODUCTDESIGNSINTHECASEOFTHEINSTRUMENTCOVER,MANYHOURSOFTRIALANDERROREXPERIMENTATIONCOULDHAVEBEENELIMINATEDBYUSINGFAST_FORM3DANDABETTERBLANKSHAPECOULDHAVEBEENDEVELOPEDFIG8COMPARISONOFFAST_FORM3DANDEXPERIMENTALBLANKSHAPESFORTHEINSTRUMENTCOVERAEXPERIMENTALLYDEVELOPEDBLANKSHAPEANDTHENOMINALCADGEOMETRYBFAST_FORM3DOPTIMALBLANKSHAPEANDTHENOMINALCADGEOMETRY3DIEANDPROCESSSIMULATIONAPPLICATIONSINORDERTOSTUDYTHEDIEDESIGNPROCESSCLOSELY,ACOOPERATIVESTUDYWASCONDUCTEDBYKOMATSULTDOFJAPANANDTHEERC/NSMAPRODUCTIONPANELWITHFORMINGPROBLEMSWASCHOSENBYKOMATSUTHISPANELWASTHEEXCAVATORSCABIN,LEFTHANDINNERPANELSHOWNINFIG9THEGEOMETRYWASSIMPLIFIEDINTOANEXPERIMENTALLABORATORYDIE,WHILEMAINTAININGTHEMAINFEATURESOFTHEPANELEXPERIMENTSWERECONDUCTEDATKOMATSUUSINGTHEPROCESSCONDITIONSSHOWNINTABLE2AFORMINGLIMITDIAGRAMFLDWASDEVELOPEDFORTHEDRAWINGQUALITYSTEELUSINGDOMETESTSANDAVISIONSTRAINMEASUREMENTSYSTEMANDISSHOWNINFIG10THREEBLANKHOLDERFORCES10,30,AND50TONWEREUSEDINTHEEXPERIMENTSTODETERMINEITSEFFECTINCREMENTALSIMULATIONSOFEACHEXPERIMENTALCONDITIONWASCONDUCTEDATTHEERC/NSMUSINGPAMSTAMPFIG9ACTUALPRODUCTCABININNERPANELTABLE2PROCESSCONDITIONSFORTHECABININNERINVESTIGATION第6页共50页FIG10FORMINGLIMITDIAGRAMFORTHEDRAWINGQUALITYSTEELUSEDINTHECABININNERINVESTIGATIONAT10TON,WRINKLINGOCCURREDINTHEEXPERIMENTALPARTSASSHOWNINFIG11AT30TON,THEWRINKLINGWASELIMINATEDASSHOWNINFIG12THESEEXPERIMENTALOBSERVATIONSWEREPREDICTEDWITHPAMSTAMPSIMULATIONSASSHOWNINFIG13THE30TONPANELWASMEASUREDTODETERMINETHEMATERIALDRAWINPATTERNTHESEMEASUREMENTSARECOMPAREDWITHTHEPREDICTEDMATERIALDRAWININFIG14AGREEMENTWASVERYGOOD,WITHAMAXIMUMERROROFONLY10MMASLIGHTNECKWASOBSERVEDINTHE30TONPANELASSHOWNINFIG13AT50TON,ANOBVIOUSFRACTUREOCCURREDINTHEPANELFIG11WRINKLINGINLABORATORYCABININNERPANEL,BHF10TONFIG12DEFORMATIONSTAGESOFTHELABORATORYCABININNERANDNECKING,BHF30TONAEXPERIMENTALBLANKBEXPERIMENTALPANEL,60FORMEDCEXPERIMENTALPANEL,FULLYFORMED第7页共50页DEXPERIMENTALPANEL,NECKINGDETAILFIG13PREDICATIONANDELIMINATIONOFWRINKLINGINTHELABORATORYCABININNERAPREDICTEDGEOMETRY,BHF10TONBPREDICTEDGEOMETRY,BHF30TONFIG14COMPARISONOFPREDICTEDANDMEASUREDMATERIALDRAWINFORLABCABININNER,BHF30TONSTRAINSWEREMEASUREDWITHTHEVISIONSTRAINMEASUREMENTSYSTEMFOREACHPANEL,ANDTHERESULTSARESHOWNINFIG15THEPREDICTEDSTRAINSFROMFEMSIMULATIONSFOREACHPANELARESHOWNINFIG16THEPREDICTIONSANDMEASUREMENTSAGREEWELLREGARDINGTHESTRAINDISTRIBUTIONS,BUTDIFFERSLIGHTLYONTHEEFFECTOFBHFALTHOUGHTHETRENDSAREREPRESENTED,THEBHFTENDSTOEFFECTTHESTRAINSINAMORELOCALIZEDMANNERINTHESIMULATIONSWHENCOMPAREDTOTHEMEASUREMENTSNEVERTHELESS,THESESTRAINPREDICTIONSHOWTHATPAMSTAMPCORRECTLYPREDICTEDTHENECKINGANDFRACTUREWHICHOCCURSAT30AND50TONTHEEFFECTOFFRICTIONONSTRAINDISTRIBUTIONWASALSO第8页共50页INVESTIGATEDWITHSIMULATIONSANDISSHOWNINFIG17FIG15EXPERIMENTALSTRAINMEASUREMENTSFORTHELABORATORYCABININNERAMEASUREDSTRAIN,BHF10TONPANELWRINKLEDBMEASUREDSTRAIN,BHF30TONPANELNECKEDCMEASUREDSTRAIN,BHF50TONPANELFRACTUREDFIG16FEMSTRAINPREDICTIONSFORTHELABORATORYCABININNERAPREDICTEDSTRAIN,BHF10TONBPREDICTEDSTRAIN,BHF30TONCPREDICTEDSTRAIN,BHF50TONFIG17PREDICTEDEFFECTOFFRICTIONFORTHELABORATORYCABININNER,BHF30TONAPREDICTEDSTRAIN,006BPREDICTEDSTRAIN,010ASUMMARYOFTHERESULTSOFTHECOMPARISONSISINCLUDEDINTABLE3THISTABLESHOWSTHATTHESIMULATIONSPREDICTEDTHEEXPERIMENTALOBSERVATIONSATLEASTASWELLASTHESTRAINMEASUREMENTSYSTEMATEACHOFTHEEXPERIMENTALCONDITIONSTHISINDICATESTHATPAMSTAMPCANBEUSEDTOASSESSFORMABILITYISSUESASSOCIATEDWITHTHEDIEDESIGNTABLE3SUMMARYRESULTSOFCABININNERSTUDY4BLANKHOLDERFORCECONTROLAPPLICATIONS第9页共50页THEOBJECTIVEOFTHISINVESTIGATIONWASTODETERMINETHEDRAWABILITYOFVARIOUS,HIGHPERFORMANCEMATERIALSUSINGAHEMISPHERICAL,DOMEBOTTOMED,DEEPDRAWNCUPSEEFIG18ANDTOINVESTIGATEVARIOUSTIMEVARIABLEBLANKHOLDERFORCEPROFILESTHEMATERIALSTHATWEREINVESTIGATEDINCLUDEDAKDQSTEEL,HIGHSTRENGTHSTEEL,BAKEHARDSTEEL,ANDALUMINUM6111SEETABLE4TENSILETESTSWEREPERFORMEDONTHESEMATERIALSTODETERMINEFLOWSTRESSANDANISOTROPYCHARACTERISTICSFORANALYSISANDFORINPUTINTOTHESIMULATIONSSEEFIG19ANDTABLE5FIG18DOMECUPTOOLINGGEOMETRYTABLE4MATERIALUSEDFORTHEDOMECUPSTUDYFIG19RESULTSOFTENSILETESTSOFALUMINUM6111,AKDQ,HIGHSTRENGTH,ANDBAKEHARDSTEELSAFRACTUREDTENSILESPECIMENSBSTRESS/STRAINCURVESTABLE5TENSILETESTDATAFORALUMINUM6111,AKDQ,HIGHSTRENGTH,ANDBAKEHARDSTEELS第10页共50页ITISINTERESTINGTONOTETHATTHEFLOWSTRESSCURVESFORBAKEHARDSTEELANDAKDQSTEELWEREVERYSIMILAREXCEPTFORA5REDUCTIONINELONGATIONFORBAKEHARDALTHOUGH,THEELONGATIONSFORHIGHSTRENGTHSTEELANDALUMINUM6111WERESIMILAR,THENVALUEFORALUMINUM6111WASTWICEASLARGEALSO,THERVALUEFORAKDQWASMUCHBIGGERTHAN1,WHILEBAKEHARDWASNEARLY1,ANDALUMINUM6111WASMUCHLESSTHAN1THETIMEVARIABLEBHFPROFILESUSEDINTHISINVESTIGATIONINCLUDEDCONSTANT,LINEARLYDECREASING,ANDPULSATINGSEEFIG20THEEXPERIMENTALCONDITIONSFORAKDQSTEELWERESIMULATEDUSINGTHEINCREMENTALCODEPAMSTAMPEXAMPLESOFWRINKLED,FRACTURED,ANDGOODLABORATORYCUPSARESHOWNINFIG21ASWELLASANIMAGEOFASIMULATEDWRINKLEDCUP第11页共50页FIG20BHFTIMEPROFILESUSEDFORTHEDOMECUPSTUDYACONSTANTBHFBRAMPBHFCPULSATINGBHFFIG21EXPERIMENTALANDSIMULATEDDOMECUPSAEXPERIMENTALGOODCUPBEXPERIMENTALFRACTUREDCUPCEXPERIMENTALWRINKLEDCUPDSIMULATEDWRINKLEDCUPLIMITSOFDRAWABILITYWEREEXPERIMENTALLYINVESTIGATEDUSINGCONSTANTBHFTHERESULTSOFTHISSTUDYARESHOWNINTABLE6THISTABLEINDICATESTHATAKDQHADTHELARGESTDRAWABILITYWINDOWWHILEALUMINUMHADTHESMALLESTANDBAKEHARDANDHIGHSTRENGTHSTEELSWEREINTHEMIDDLETHESTRAINDISTRIBUTIONSFORCONSTANT,RAMP,ANDPULSATINGBHFARECOMPAREDEXPERIMENTALLYINFIG22ANDARECOMPAREDWITHSIMULATIONSINFIG23FORAKDQINBOTHSIMULATIONSANDEXPERIMENTS,ITWASFOUNDTHATTHERAMPBHFTRAJECTORYIMPROVEDTHESTRAINDISTRIBUTIONTHEBESTNOTONLYWEREPEAKSTRAINSREDUCEDBYUPTO5THEREBYREDUCINGTHEPOSSIBILITYOFFRACTURE,BUTLOWSTRAINREGIONSWEREINCREASEDTHISIMPROVEMENTINSTRAINDISTRIBUTIONCANINCREASEPRODUCTSTIFFNESSANDSTRENGTH,DECREASESPRINGBACKANDRESIDUALSTRESSES,INCREASEPRODUCTQUALITYANDPROCESSROBUSTNESSTABLE6LIMITSOFDRAWABILITYFORDOMECUPWITHCONSTANTBHFFIG22EXPERIMENTALEFFECTOFTIMEVARIABLEBHFONENGINEERINGSTRAININANAKDQSTEELDOMECUP第12页共50页FIG23SIMULATEDEFFECTOFTIMEVARIABLEBHFONTRUESTRAININANAKDQSTEELDOMECUPPULSATINGBHF,ATTHEFREQUENCYRANGEINVESTIGATED,WASNOTFOUNDTOHAVEANEFFECTONSTRAINDISTRIBUTIONTHISWASLIKELYDUETOTHEFACTTHEFREQUENCYOFPULSATIONTHATWASTESTEDWASONLY1HZITISKNOWNFROMPREVIOUSEXPERIMENTSOFOTHERRESEARCHERSTHATPROPERFREQUENCIESRANGEFROM5TO25HZ3ACOMPARISONOFLOADSTROKECURVESFROMSIMULATIONANDEXPERIMENTSARESHOWNINFIG24FORAKDQGOODAGREEMENTWASFOUNDFORTHECASEWHERE008THISINDICATESTHATFEMSIMULATIONSCANBEUSEDTOASSESSTHEFORMABILITYIMPROVEMENTSTHATCANBEOBTAINEDBYUSINGBHFCONTROLTECHNIQUESFIG24COMPARISONOFEXPERIMENTALANDSIMULATEDLOADSTROKECURVESFORANAKDQSTEELDOMECUP5CONCLUSIONSANDFUTUREWORKINTHISPAPER,WEEVALUATEDANIMPROVEDDESIGNPROCESSFORCOMPLEXSTAMPINGSWHICHINVOLVEDELIMINATINGTHESOFTTOOLINGPHASEANDINCORPORATEDTHEVALIDATIONOFPRODUCTANDPROCESSUSINGONESTEPANDINCREMENTALFEMSIMULATIONSALSO,PROCESSIMPROVEMENTSWEREPROPOSEDCONSISTINGOFTHEIMPLEMENTATIONOFBLANKHOLDERFORCECONTROLTOINCREASEPRODUCTQUALITYANDPROCESSROBUSTNESSTHREESEPARATEINVESTIGATIONSWERESUMMARIZEDWHICHANALYZEDVARIOUSSTAGESINTHEDESIGNPROCESSFIRST,THEPRODUCTDESIGNPHASEWASINVESTIGATEDWITHALABORATORYANDINDUSTRIALVALIDATIONOFTHEONESTEPFEMCODEFAST_FORM3DANDITSABILITYTOASSESSFORMABILITYISSUESINVOLVEDINPRODUCTDESIGNFAST_FORM3DWASSUCCESSFULATPREDICTINGOPTIMALBLANKSHAPESFORARECTANGULARPANANDANINDUSTRIALINSTRUMENTCOVERINTHECASEOFTHEINSTRUMENTCOVER,MANYHOURSOFTRIALANDERROREXPERIMENTATIONCOULDHAVEBEENELIMINATEDBYUSINGFAST_FORM3DANDABETTERBLANKSHAPECOULDHAVEBEENDEVELOPEDSECOND,THEDIEDESIGNPHASEWASINVESTIGATEDWITHALABORATORYANDINDUSTRIALVALIDATIONOFTHEINCREMENTALCODEPAMSTAMPANDITSABILITYTOASSESSFORMINGISSUESASSOCIATEDWITHDIEDESIGNTHISINVESTIGATIONSUGGESTEDTHATPAMSTAMPCOULDPREDICTSTRAINDISTRIBUTION,WRINKLING,NECKING,ANDFRACTUREATLEASTASWELLASAVISIONSTRAIN第13页共50页MEASUREMENTSYSTEMATAVARIETYOFEXPERIMENTALCONDITIONSLASTLY,THEPROCESSDESIGNSTAGEWASINVESTIGATEDWITHALABORATORYSTUDYOFTHEQUALITYIMPROVEMENTSTHATCANBEREALIZEDWITHTHEIMPLEMENTATIONOFBLANKHOLDERFORCECONTROLTECHNIQUESINTHISINVESTIGATION,PEAKSTRAINSINHEMISPHERICAL,DOMEBOTTOMED,DEEPDRAWNCUPSWEREREDUCEDBYUPTO5THEREBYREDUCINGTHEPOSSIBILITYOFFRACTURE,ANDLOWSTRAINREGIONSWEREINCREASEDTHISIMPROVEMENTINSTRAINDISTRIBUTIONCANINCREASEPRODUCTSTIFFNESSANDSTRENGTH,DECREASESPRINGBACKANDRESIDUALSTRESSES,INCREASEPRODUCTQUALITYANDPROCESSROBUSTNESSITCANBEEXPECTEDTHATIMPROVEMENTSINDRAWABILITYWOULDBEFURTHERENHANCEDBYOPTIMIZINGTHEVARIATIONOFTHEBHFINFUNCTIONOFTIMEFURTHER,GOODAGREEMENTWASFOUNDFOREXPERIMENTALLYMEASUREDANDNUMERICALLYPREDICTEDLOADSTROKECURVESINDICATINGTHATFEMSIMULATIONSCANBEUSEDTOASSESSTHEFORMABILITYIMPROVEMENTSTHATCANBEOBTAINEDUSINGBHFCONTROLTECHNIQUES第14页共50页DIEPOSITIONININDUSTRIALPRODUCTIONMOLDISAHIGHVOLUMEPRODUCTSWITHTHESHAPETOOL,ISTHEMAINPROCESSOFINDUSTRIALPRODUCTIONEQUIPMENTWITHMOLDCOMPONENTS,WITHHIGHEFFICIENCY,GOODQUALITY,LOWCOST,SAVINGENERGYANDRAWMATERIALSANDASERIESOFADVANTAGES,WITHTHEMOLDWORKPIECESPOSSESSHIGHACCURACY,HIGHCOMPLEXITY,HIGHCONSISTENCY,HIGHPRODUCTIVITYANDLOWCONSUMPTION,OTHERMANUFACTURINGMETHODSCANNOTMATCHHAVEALREADYBECOMEANIMPORTANTMEANSOFINDUSTRIALPRODUCTIONANDTECHNOLOGICALDEVELOPMENTTHEBASISOFTHEMODERNINDUSTRIALECONOMYTHEDEVELOPMENTOFMODERNINDUSTRIALANDTECHNOLOGICALLEVELDEPENDSLARGELYONTHELEVELOFINDUSTRIALDEVELOPMENTDIE,SODIEINDUSTRYTONATIONALECONOMICANDSOCIALDEVELOPMENTWILLPLAYA