The initial blank geometry plays an important role on the quality of deep drawn parts. The present paper develops a new approach for optimizing the blank shape. In this approach the three-dimensional model of the final part is used to design an initial blank geometry for the given part. The deep drawing process is simulated using the initial blank shape. The blank is optimized in an iterative process based on the shape error and the deformation path length of the boundary nodes of the blank in the previous iteration. Optimum blank shapes for four case studies are determined. The results of the presented method are compared with some other methods in the literature and the presented method is found to be more efficient.
KuwabaraT.SiW. H.PC-based blank design system for deep-drawing irregularly shaped prismatic shells with arbitrarily shape flange. J. Mater. Process. Technol., 1997, 63, 89–94.
2.
KimN.KobayashiS.Blank design in rectangular cup drawing by an approximate method. Int. J. Machine Tool Des. Res., 1986, 26(2), 125–135.
3.
ZakyA. M.NassrA. B.El-SebaieM. G.Optimum blank shape of cylindrical cups in deep drawing of anisotropic sheet metal. J. Mater. Process. Technol., 1998, 76, 203–211.
4.
GuoY. Q.BatozJ. L.NaceurH.BouabdallahS.MercierF.BarletO.Recent developments on the analysis and optimum design of sheet metal forming parts using a simplified inverse approach. Comput. Struct., 2000, 78, 133–148.
5.
KuT. W.LimH. J.ChoiH. H.HwangS. M.KingB. S.Implementation of backward tracing scheme of the FEM to blank design in sheet metal forming. J. Mater. Process. Technol., 2001, 111, 90–97.
6.
NaceurH.GuoY. Q.BatozJ. L.Blank optimization in sheet metal forming using an evolutionary algorithm. J. Mater. Process. Technol., 2004, 151, 183–191.
7.
ParsaM. H.PourniaP.Optimization of initial blank shape predicted based on inverse finite element method. Finite Elem. Anal. Des., 2007, 43, 218–233.
8.
AziziR.AssempourA.Applications of linear inverse finite element method in prediction of the optimum blank in sheet metal forming. Mater. Des., 2008, 29(10), 1965–1972.
9.
AziziR.Different implementations of inverse finite element method in sheet metal forming. Mater. Des., 2009, 30(8), 2975–2980.
10.
ParkS. H.YoonJ. W.YangD. Y.KimY. H.Optimum blank design in sheet metal forming by the deformation path iteration method. Int. J. Mech. Sci., 1999, 41(10), 1217–1232.
11.
PegadaV.ChunY.SanthanamS.An algorithm for determining the optimal blank shape for the deep drawing of aluminum cups. J. Mater. Process. Technol., 2002, 125–126, 743–750.
12.
ShimH.SonK.Optimal blank shape design by the iterative sensitivity method. Proc. IMechE, Part B: J. Engineering Manufacture, 2002, 216(6), 867–878.
13.
SonK. C.ShimH. B.Optimal blank shape design using the initial velocity of boundary nodes. J. Mater. Process. Technol., 2003, 134(1), 92–98.
14.
VafaeesefatA.Optimum blank shape design in sheet metal forming by boundary projection method. Int. J. Mater. Form., 2008, 1(1), 189–192.
15.
HammamiW.PadmanabhanR.OliveiraM. C.BelHadjSalahH.AlvesJ. L.MenezesL. F.A deformation based blank design method for formed parts. Int. J. Mech. Mater. Des., 2009, 5(4), 303–314.
16.
PadmanabhanR.OliveiraM. C.BaptistaA. J.AlvesJ. L.MenezesL. F.Numerical study on the influence of initial anisotropy on optimal blank shape. Finite Elem. Anal. Des., 2009, 45(2), 71–80.
17.
AzaouziM.NaceurH.DelamézièreA.BatozJ. L.BelouettarS.An heuristic optimization algorithm for the blank shape design of high precision metallic parts obtained by a particular stamping process. Finite Elem. Anal. Des., 2008, 44(14), 842–850.
