Design And Development Of Pre-process System For Embossing Process Simulation

Embossing is one of complex process of metal plastic forming. Engineers optimize embossing process according to try out design model by their experience repeatedly. It will lead to the increasing of the design cost as there are so many kinds of materials being used in the process. The numerical simulation based on the finite element method takes more and more important role in the embossing process, which can optimize the embossing process at the beginning of the design stage through predicting the forming force and defects such as crack, insufficient, skip line etc.The research of this paper is the important part of the project"Embossing Process Simulation and Optimization", which is a cooperating research project between the State Key Lab. of Die and Mould Technology and the Shenyang Minting Company.In this paper, the author studied the relative technology to construct the pre-process system of embossing simulation including the frame work, the data structure and the data steam, which based on the system analysis method. The system has a character of great database, professional, friendly interface and simple operation process etc.In this paper, the author developed the solid element mesh algorithm based on the 2-D mesh algorithm. The author developed the simplify algorithm of mesh display to optimize the data display. The author developed the tool mesh optimizing algorithm based on the STL files, which reduced the number of the tool mesh through element merging with the permission of the precision of the simulation. The author also developed the algorithm of virtual assembly of the FEM model to simplify the operation.At the end of this paper, the author introduced the application of the software with the forming optimization method of one coin.