ADirectEngineering Approach to the Design of Draw Die Binder Developmensts 2020-01-0952
FEA computer simulations give good “scientific” predictions of how a draw die will perform; and when coupled with iterating optimizers will even optimize a few of the many dimensions. But there are still many questions unanswered. The simulator does just what the name says; it “simulates” the design given to it. The simulation designs nothing. An alternative and novel method of structuring the draw die binder development design process facilitates an “engineering” approach of calculating the formability, kinematics and friction to get the optimum dimensions for parametric addendum features of the binder development directly. The procedure is to first define and quantify the desired performance such as no splits, no wrinkles, no spring back distortions (after flanging), “x” amount of work strengthening, robustness to normal and reasonable material and processing variations, optimum blank size and of course the mechanical die standards. These specifications become the boundary conditions for the calculations. Then the feasibility of the product design is evaluated resulting in an energy continuum at the edge-of-part defined as strains to be imposed, displacements to be accommodated and wrap lengths required at strategic locations. The product evaluation should be done during the architecture phase of product design once the typical sections, cut lines, seal contact lines and mounting patterns are established, but not completely surfaced. A wire frame of the binder development (including draw bead depths, draw-in amounts and blank size) is then designed based on the energy continuum and without referencing product geometry and performance requirements. The actual CAD die face surfaces are then created and productionized.
M105: Sheet Metal forming Technology