ESI Die Starter: A New Approach to Manage Early Feasibility in Sheet Metal Forming

摘要

Virtual stamping engineering is now used across the entire sheet metal forming process, from early feasibility of designs and initial cost estimation to final virtual try-out and inspection. Never-the-less, there remains a compelling need to shorten product development time and especially to accelerate the early stages of the process. Die Starter, a new solution developed by ESI Group, allows a die tool engineer to drastically reduce the number of iterations needed to establish a feasible tool design. This innovative system automatically designs the first quick die face ("initial die face") by generating binder and addendum surfaces (NURBS surfaces), including beads values and blank contour. Die Starter also improves on the initial die face using a mathematical optimization algorithm based on feasibility criteria (avoiding splits, wrinkles) to automatically generate geometrical modifications of the binder and addendum, and optimizes draw bead forces to achieve forming goals with minimal material usage. This paper presents a description of the new approach and methodology of Die Starter. Some industrial examples are presented; from the part geometry to final die face (initial die face and optimization).