Shape- and topology-based structural die design using differential evolution and response surface methodology for sheet metal forming

Abstract

The goal of this research is to describe how simulation and topology design can be used as a die design frame tool to introduce optimal die design structures with the desired maximum rigidity and minimum deformations using response surface methodology and differential evolution algorithms. In the simulation process, not only die deflection, but also press table deflection is taken into account in order to achieve more realistic results. The validation of the present approach is evaluated by a comparison of test and simulation results. In the experimental test, acceleration and strain data were measured from critical points of the die structure in order to obtain the maximum displacement and stress values. The optimal shape parameters for the die structure were obtained using response surface methodology and differential evolution as a fundamental optimisation technique. Significant results were obtained: The mass was reduced approximately about 24 %, and the current maximum stress decreased approximately about 72 %. By using this methodology in the design stage of die and sheet metal stamping, major improvements can be made to the vehicle development process, such as reducing the weight and the cost of die, reducing the labour costs during the tryout process and reducing the environmental damage and CO2 emissions by reducing the amount of cast iron.