Finite Element Simulation for Blank Shape Optimization in Sheet Metal Forming

The aim of this article is to propose an algorithm to predict the initial blank shape from the desired part in the sheet metal forming process. The algorithm is based on iterative finite element (FE) sheet metal forming simulations. To find a new blank shape, the boundary of the part is projected on the deformed blank. The transformation of the projected boundary on the initial blank defines the new blank boundary. Since the proposed algorithm is based on three-dimensional projections, it is not restricted to the part shape and the initial guess of the blank shape. The proposed algorithm is applied to square cup and oil pan drawings to confirm its validity. The results show that the proposed method can reach the optimum blank shape within a few iterations. The outcomes are in good agreement with experimental data.