An advanced technique for determining NC machining tool path to fabricate drawing die surface considering non-uniform th
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ORIGINAL ARTICLE
An advanced technique for determining NC machining tool path to fabricate drawing die surface considering non-uniform thickness distribution in stamped blank Zhihui Gong 1 & Mandeep Singh 2 & Dongbin Wei 2 Received: 2 February 2020 / Accepted: 24 September 2020 / Published online: 13 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Drawing process represents a significant area of production technology since it influences the feasibility of producing auto-body die panels. In the drawing process, the plastic deformation of blank is not uniform due to the intermittent deformation behavior of the material. This primes a non-uniform thickness distribution in the formed panels, which directly affects the die life and the quality of panels. In the presented study, a new algorithm was proposed for constructing the numerical control machining tool path for the new die surface obtained from FEM simulation and mesh mapping. The commercial package LS-DYNA was employed for the FEM simulation and to calculate the thickness distribution in the drawn workpiece. In order to construct the new numerical control machining tool path according to the new die surface, the positions of all cutter location points relative to the movement of new die mesh were determined. A set of forming die was machined using the proposed algorithm to fabricate a real workpiece of steel DC04. A comparison between the measured thicknesses in the fabricated workpiece and the FEM simulation results shows that they agree with each other very well, which directly validates the proposed algorithm. The developed method can improve product quality, increase production efficiency, and reduce labor intensity. Keywords Drawing die . Auto-body panel . FEM simulation . Tool path
1 Introduction The use of high precise auto-body panels has increased in the automobile industry over the years [1, 2]. Drawing is the most significant forming process to fabricate a complex and accurate auto-body panel [3–5]. The popularity of this forming process is mainly due to its high productivity and the ability to offer high strength. However, one of the major concerns in the drawing process is surface deflection in the formed panels [6, 7], which is a kind of micro distortion of the local surface due to non-uniform local residual stress after springback. Whether the gap between the surfaces of punch and die can match the non-uniform thickness distribution in the stamped blank has a significant influence on the surface deflection. In * Dongbin Wei [email protected] 1
State Key Laboratory of Advanced Design and Manufacture for Vehicle Body, Hunan University, Changsha 410082, China
2
School of Mechanical and Mechatronic Engineering, University of Technology Sydney, Ultimo, NSW 2007, Australia
the drawing process, the plastic deformation of the blank is not uniform due to the intermittent deformation behavior of the material, which primes a non-uniform thickness distribution in the stamped workpieces [8–11]. In order to avoid high
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