Optimization methods for complex sheet metal stamping computer aided engineering

Nowadays, sheet metal stamping processes design is not a trivial task due to the complex issues to be taken into account (complex shapes forming, conflicting design goals and so on). Therefore, proper design methodologies to reduce times and costs have to be developed mostly based on computer aided procedures. In this paper, a computer aided approach is proposed with the aim to offer a methodology able to solve very complex sheet metal stamping processes, in particular a progressive design approach based on the integration between numerical simulations and optimization methodologies is presented. In particular, Response Surface Method, Moving Least Squares approximation and Pareto optimal solutions search techniques were applied in order to design two different complex 3D stamping operations. The proposed design procedure is able to verify the necessity of a spatially differentiated restraining forces approach and to design the best policy for them. In particular, different part “quality” indicators were monitored such as springback occurrence and thinning. An explicit/forming-implicit/springback approach was utilized to develop the numerical simulations. To sum up, a new and flexible design methodology is proposed, able to: deal with complex sheet metal stamping processes; investigate many possible technological scenarios; carry out a set of reliable solutions able to satisfy different design requirements; offer different optimization possibilities in order to take in to account all the sheet metal stamping design issues.