Research On Key Technologies Of Structure Optimization Of Die Base For Multi-position Progressive Die

Multi-position progressive die is a kind of complex, precise stamping die, which is suitable for automatic production in all kinds of stamping industry. With the improvement of the stamping technic, progressive die develops in the direction of large-scale, complex and precise. The increasing stamping tonnage of progressive die has become a irreconcilable conflict with the accuracy requirement of its product under traditional design methods. Traditional design methods on the one hand lead to higher material and energy cost,on the other hand affect the stamping quality of products because of unreasonable structure design. Currently,research on structure topology optimization design of multi-position progressive die based on stamping simulation has not been reported. Research on key technologies of structure optimization of die base for multi-position progressive die has a certain practical significance and research value.In this thesis, regarding multi-position progressive die as the research object, the finite element simulation technology of blanking procedure in multi-position progressive stamping process, the cross-platform mapping method of progressive die forming load, the analytical method about matrix structure of progressive die, the topology optimization technology about matrix structure of progressive die were studied respectively. The main research contents and conclusions of this paper are summarized as follows:1) Pre- simulated the sheet blanking, then basing the blank division technology of pre-simulation result and Local grid refinement technology, each punch procedure in the progressive stamping process for a guide rail were simulated, the Finite element simulation of punch procedure of complicated shape in multi-position progressive stamping process was accomplished. The blanking force of simulated result and theoretical result were contrastive analysis.2) The data form of FE model in Deform-3D and Hypermesh were analyzed, the methods of getting each model data in before and post file of Deform-3D were induced. The Load mapping method was studied, the matching method between original load node and the corresponding target unit and the interpolation method for different target unit were summarized. A load mapping tool was exploited, which could make the punch simulation load mapping between the model in Deform-3D and the Mould structure analysis model in Hypermesh, the force boundary conditions were offered for progressive die structure analysis.3) With Radioss software, the load mapping method and uniformly distributed load method were used respectively to analyze the progressive die structure of car connector which use combination die structure, and these two method were contrasted. The results show that, the deformation distribution of die base obtained from two methods were basically the same. Thus for the progressive die which use combination die structure, using uniformly distributed load method to replace the load mapping method to analyze static structure, could decrease the model, enhance analytic efficiency and assure the reliability of analysis result.4) With Radioss software, multi-loading structure was analyzed by using uniformly distributed load method for progressive die structure of car connector which use combination die structure, the target of topological optimization for die base were confirm. With Optistruct software, to decrease the structural distortion, topology optimization iteration basing on variable density method was used in die base to obtain the best unit material density distribution. UG software was used to optimized reconstruction for die base structure. The results show that, the reconstructed die base structure is conform to the requirements of the optimization.5) The actual stain of the die base of a car connector progressive die was measured by using electro motive strain method. The messurement results were compared with the simulation values. The results show that the structure analysis methods and structure topology optimization method proposed in this thesis is reliable.