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Research Papers

Die Face Morphing With Formability Assessment

[+] Author and Article Information
Liang Zhou

Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109zhl@umich.edu

S. Jack Hu

Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109jackhu@umich.edu

Thomas B. Stoughton

 Research and Development General Motors Corp., Warren, MI 48090thomas.b.stoughton@gm.com

J. Manuf. Sci. Eng 133(1), 011003 (Jan 24, 2011) (11 pages) doi:10.1115/1.4003333 History: Received October 23, 2009; Revised November 18, 2010; Published January 24, 2011; Online January 24, 2011

A die face morphing concept was recently introduced for quick die design for evolutionary products from their prior generations. Based on this concept, this paper proposes a strain increment method for early formability assessment by predicting strain distribution directly from the part-to-part mapping process. This method consists of mapping the finite element mesh to the part geometry, solving a part-to-part mapping function with smoothness and strain gradient penalties, and extracting strain increment from geometric morphing. It is shown, through a case study, that the strain field estimated by the proposed strain increment method compares well with that from the direct finite element analysis. Since this method does not require the knowledge on new die surface, such formability assessment can serve as a tool for early manufacturing feasibility analysis on the new part design.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Die face morphing from a prior generation to a new generation (8)

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Figure 2

Die face morphing concept

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Figure 3

NURBS curves defined by 16 control points

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Figure 4

Part-to-part mapping by FFD

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Figure 5

Mapping of finite element nodes (dots) onto geometry (X denotes B-spline control points)

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Figure 6

Lamina coordinate and fiber direction in a shell element (31)

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Figure 7

Comparison of displacement fields with and without smoothing function

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Figure 8

3D cup drawing case study: (a) shape of the existing part, (b) shape of the new part, and (c) 1/8 modeling (x: NURBS control points of the existing part; o: NURBS control points of the new part)

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Figure 9

Mapping of finite element mesh onto geometry

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Figure 10

Part-to-part mapping solved from Eq. 22

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Figure 11

A new die face generated from the evolutionary die morphing method

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Figure 12

Comparison of the part generated by the morphed die (point cloud) and the desired part (surface)

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Figure 13

Strain prediction on the existing and new parts by FEA

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Figure 14

Strains from edge to center of the new part

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