In the field of stamping die design, CAE simulation technology provides a powerful boost for optimizing the forming process. It can predict potential problems in advance by simulating the stamping process, so as to improve the design in a targeted manner. The following analyzes its specific applications and optimization methods from multiple levels.
CAE simulation technology can visualize the stamping process. In the early stage of design, engineers import the three-dimensional model of the stamping die and the sheet into the CAE software, set parameters such as material properties, stamping speed, and die gap, and the software can simulate the entire stamping process. By intuitively presenting the deformation of the sheet in the mold, the material flow trend, stress distribution state, etc. can be clearly observed. For example, when simulating the stamping of automobile cover parts, it is possible to check in real time whether the sheet has defects such as wrinkling and cracking, which helps engineers find design loopholes in advance, avoid errors caused by lack of experience, and reduce the cost of later modifications.
Using CAE simulation to analyze the material flow law can effectively optimize the mold structure design. Molds of different shapes and sizes will cause differences in the flow path of the sheet during stamping. Through CAE simulation, the filling of materials in various parts of the mold can be analyzed to determine whether there are areas of poor flow or excessive accumulation. If it is found that the material is not fully filled in the corners of the mold, engineers can adjust the mold's structural parameters such as the fillet radius and draft angle to improve the material flow state, so that the sheet can fill the mold cavity more evenly, improve the product molding quality, and reduce the mold wear caused by uneven material flow, thereby extending the mold life.
CAE simulation can also accurately predict the stress and strain distribution during the stamping process. During stamping, complex stress and strain will be generated inside the sheet. If the stress is concentrated in certain parts, it may cause product cracking or mold damage. With the help of CAE technology, the stress and strain values of the sheet and mold at each stage can be calculated and displayed in the form of a cloud map. For example, if stress concentration is found on the shoulder of the mold punch, engineers can optimize the transition structure of the punch, increase the fillet or change the cross-sectional shape, reduce the stress concentration, improve the strength and reliability of the mold, and avoid quality defects of the product due to stress problems.
Optimizing process parameters through CAE simulation is the key to improving stamping efficiency and quality. Stamping process parameters such as stamping speed, blank holder force, friction coefficient, etc. have a significant impact on the molding results. CAE software can perform multiple sets of simulation analysis on these parameters and compare the forming effects under different parameter combinations. For example, change the size of the blank holder force to observe whether the sheet is wrinkled or torn; adjust the stamping speed to analyze the stability of the material flow. Engineers can select the optimal combination of process parameters based on the simulation results, which can not only ensure product quality, but also improve production efficiency, reduce energy consumption and cost.
CAE simulation technology helps to solve the springback problem and improve product dimensional accuracy. After stamping, the sheet will rebound due to elastic recovery, resulting in product size not being consistent with the design. Using CAE simulation, the direction and value of sheet springback can be predicted. According to the prediction results, engineers can reversely compensate the profile when designing the mold, so that the stamped product will meet the dimensional requirements after rebounding. In addition, the springback amount can be reduced by adjusting the process parameters, such as adding a correction process and optimizing the distribution of the blank holder force, to ensure that the product dimensional accuracy meets the requirements.
In the design of multi-process stamping die, CAE simulation can optimize the process arrangement and mold layout. For the stamping of complex parts, multiple processes are often required to complete. By simulating the forming process of each process through CAE simulation, it is possible to analyze whether the connection between the processes is reasonable and determine the impact of the forming results of the previous process on the subsequent processes. For example, if it is found that the residual stress generated in a certain process will cause deformation in the subsequent process, the engineer can adjust the process sequence or modify the mold structure to coordinate the processes, ensure the smooth progress of the entire stamping process, and improve product quality and production efficiency.
The combination of CAE simulation technology and actual production can also achieve continuous optimization. In actual stamping production, production data can be fed back to the CAE simulation model to correct and improve the model to make it more in line with the actual situation. By continuously accumulating production data and optimizing simulation models, engineers can more accurately predict problems in the stamping process, further optimize mold design and forming process, form a virtuous cycle of design, simulation, production, feedback, and optimization, promote the continuous improvement of stamping die design and forming process, and enhance the competitiveness of enterprises.
