On the Optimization of the Punch-Die Shape: An Application of New Concepts of Tools Geometry Alteration for Springback Compensation

This work here presented concerns the activities of stamping tools alterations of an automotive component done thanks optimization technologies. The process of nominal geometry alteration of a complete stamping die is traditionally based on the experience of the try-out people who manually modify the tools in order to compensate geometrical differences due to springback under a Trial-and-Error approach and often the restroking die needs so substantial modifications to lead to be partially re-designed . With the introduction of new steels, high tensile steels with considerable springback effects, this approach become more and more difficult. Trial and error techniques used in the reality in the try-out phase now are possible in the development phase thanks to morphing technologies in HyperForm. But an innovative technique, developed at Altair Engineering, give the possibility to proceed automatically and systematically: the approach, general and flexible, is based on a orthonormal base of deformation functions that allows the automatic management of the geometry alteration of the die. Not least the principle to obtain a small geometry error after the cutting stages, before the restroking stage. The geometry alteration are hence applied on the draw tools. The process is automatically managed by an optimization algorithm in Altair HyperStudy, who manages the geometrical parameters who define the die shape in order to converge to the optimal die shape. This paper shows how the morphing approach and the automatic deformation function approach converge to the same solution and the improvements obtained in the reality.