Sheet Hydroforming Process Numerical Model Improvement Through Experimental Results Analysis

摘要

The increasing application of numerical simulation in metal forming field has helped engineers to solve problems one after another to manufacture a qualified formed product reducing the required time [1]. Accurate simulation results are fundamental for the tooling and the product designs. The wide application of numerical simulation is encouraging the development of highly accurate simulation procedures to meet industrial requirements. Many factors can influence the final simulation results and many studies have been carried out about materials [2], yield criteria [3] and plastic deformation [4,5], process parameters [6] and their optimization. In order to develop a reliable hydromechanical deep drawing (HDD) numerical model the authors have been worked out specific activities based on the evaluation of the effective stiffness of the blankholder structure [7]. In this paper after an appropriate tuning phase of the blankholder force distribution, the experimental activity has been taken into account to improve the accuracy of the numerical model. In the first phase, the effective capability of the blankholder structure to transfer the applied load given by hydraulic actuators to the blank has been explored. This phase ended with the definition of an appropriate subdivision of the blankholder active surface in order to take into account the effective pressure map obtained for the given loads configuration. In the second phase the numerical results obtained with the developed subdivision have been compared with the experimental data of the studied model. The numerical model has been then improved, finding the best solution for the blankholder force distribution.