Deep-Drawing Tool Geometry Using Hybrid Springback Compensation
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Solution Overview
Problem
The existing methods for producing forming dies for reshaping components, such as those for motor vehicles, are time-consuming and costly due to the iterative process of determining the die geometry to achieve a desired final shape after springback.
Innovation Solution
A method involving simulations on an electronic computing device to calculate and invert stress states and vector fields, allowing for the determination of design data that enables the production of forming dies with a geometry that results in the desired final shape with minimal iterations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the geometry of the forming die is determined using conventional iterative methods, then the component achieves the desired final shape after springback, but the production process becomes time-consuming and costly
Solution Approach 1:
The patent applies preliminary action by performing stress inversion calculations before the actual forming process. The stress state is inverted in advance to pre-compensate for springback effects, allowing the die geometry to be determined more accurately in fewer iterations rather than relying on conventional trial-and-error approaches
Solution Approach 2:
The patent replaces the conventional mechanical iterative adjustment process with computational methods. Instead of physically adjusting die geometry through multiple iterations, the invention uses stress inversion algorithms and simulations to calculate the optimal die geometry directly, substituting mechanical trial-and-error with mathematical computation
2Manufacturing precision
If the geometry of the forming die is determined using conventional iterative methods, then the desired final shape is achieved, but the production cost increases
Solution Approach 1:
The patent replaces costly mechanical iterative adjustment processes with computational stress inversion methods. By using algorithms to calculate the inverted stress state and determine optimal die geometry, the invention eliminates the need for expensive physical prototypes and repeated die modifications
Solution Approach 2:
The patent creates a computational model (copy) of the stress state and inverts it virtually to determine the optimal die geometry. This digital copying and inversion process allows for accurate die design without requiring multiple physical iterations, reducing manufacturing costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the number of iterations required to achieve the desired final geometry, making the production of forming dies more time-saving and cost-effective.
Implementation Method 1
a stress state which characterizes the internal stresses of the workpiece kept in the first deformed state using the closed die parts is calculated
Implementation Method 2
the component is deformed automatically or independently, starting from the first deformed state, which means that, for example, the component comes into a second deformed state. This deformation of the component, resulting from the opening of the die parts and from the internal stresses described is also designated as springing up, spring up, springing back, spring back
Data Source
AI summary
Methods, systems, and devices for determining construction data for producing a forming die are provided. Using an electronic computing device, a simulation is carried out that includes moving die parts of a die toward each other to a closed position, reshaping a workpiece reshaping a workpiece from an initial state to a first deformed state due to the moving of the die parts to the closed position, keeping the die parts at least temporarily in the closed state to maintain the workpiece in the first deformed state, moving the die parts away from each other to an open position, and deforming the workpiece to a second deformed state from the first deformed state due to internal stresses of the workpiece and due to moving of the die parts to the open position. A geometry of a new die part that influences the reshaping is determined.