Analysis of the influencing factors of the mold result on the production process

In order to better design the forming mold, in the actual load cases, due to the different geometric dimensions and material quality of the parts to be processed, higher forces will appear, and new operating methods are required. With the help of the virtual forming process flow chain, the application of new-type plates can be reduced, and the development of new processing techniques associated with it can be simplified. Part simulation molding technology is a relatively fixed part of the part production stage and mold design process.

The modeling process of the simulation will be affected by the deformed body of the holder of the blank holder (the substitute model is described paragraph by paragraph in the simulation). This force acts on the different flows of materials. In the real process, it is necessary to consider the force determined by the geometric size and the controlled forming result with the help of the stretched thin wall in the mold. It has been possible to find defects such as thinning of wall thickness, bending and stretching in the virtual simulation. Therefore, simulation can be used to influence the molding result at the production stage. So far, the optimization of the sheet metal parts has been started, because the effect of the parts to be processed can be observed in the virtual simulation. (Guide: Analysis of the anti-fracture ability of common cold mold material processing)

In addition, secondary influencing factors such as the state of the mold itself, the state of the stamping machine itself, or the overall performance between the batch stamping machine and the mold, etc. will also have an impact on the drawing results. These factors need to be partially or very carefully considered as parameters in simulation molding. Only after using a special application system to study the relationship between simulation molding and production mold design can a closed process chain be obtained, so that the manufacturing process of the production mold can be optimized from the load point of view. Now a newly developed method of transferring the molding force can link the simulation of plastic molding with the design of production molds.

First of all, a CAD model of the production mold must be established on the basis of the CAD data. Next, people will prepare CAD surface data for production molds for meshed finite element analysis containing two-dimensional surface elements. On the basis of two-dimensional surface grids, three-dimensional continuous elements (tetrahedrons) are used to construct three-dimensional grids. The mesh topology of the simulation molding is different from the volume mesh of the production tool. Therefore, the simulation molding is composed of faceted elements; in contrast, the grid structure of the mold is composed of three-dimensional tetrahedral elements.

The main problem is that the contact pressure obtained by modeling the part will be transferred to the working surface of the mold. The contact pressure is determined by the internal stress state of the stretched part. In the next step, one converts the contact pressure into the boundary conditions of the mold mesh. Commercial software can only provide solutions for the entire process, that is to say, it means additional costs for the manual modeling of production molds. The realization of the process steps requires the development of a special application software system. With this kind of software, you can take advantage of the process that has been developed without incurring additional costs.

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