基于变密度法的级进模模具结构拓扑优化设计

Structural Topological Optimization of Multi-Position Progressive Die Based on Variable Density Method

针对多工位级进模模具,提出了一种基于变密度法的级进模模具结构拓扑优化方法。先通过板材冲压成形有限元数值模拟得到变形板料对模具的作用力,利用自主开发的载荷映射工具构建级进模模具结构分析的力边界条件;再通过模具结构分析,明确模具结构优化的空间;最后结合拓扑优化算法对模具结构进行了优化设计。以某汽车连接器件级进模模具为例对该方法加以验证,与按传统方法设计的模具相比,优化重构后的模具在重量保持不变的情况下最大变形量减小了36.5%。对优化重构后的级进模在冲压成形过程中的应变值进行了测量,应变实测值与结构分析结果比较吻合,表明文中所提出的级进模模具结构拓扑优化方法是切实可靠的。

Aimed at optimizing the structure of multi-position progressive die,a method of structural topological optimization based on variable density method was proposed.The boundary forces that the deformable blank acting on the die were obtained from the sheet metal forming simulation,and then,the force boundary conditions were set up based on the independently developed load mapping program.The die structure design space was achieved according to die structure analysis,and then,the die structure optimization design was carried out depended on topology optimization algorithm,and was further verified by the multi-position progressive die of the automotive connector.Compared with the original die structure,under the condition that the weight of the optimized die keeps unchanged,the maximum deformation reduces by 36.5%.The strain values on the optimized die during stamping process were tested.It shows that the numerical results conform well to the experimental ones.The result also proves that the proposed method of topology optimization in multi-position progressive die is effective and reliable.