Simulation of residual stresses in stamping dies
2008 (English)In: Proceedings of the IDDRG 2008 Conference : Best in class stamping, 16-18 June 2008, Olofström, Sweden / [ed] Nader Asnafi, Olofström: Industriellt utvecklingscentrum i Olofström AB , 2008, 765-776 p.Conference paper (Refereed)
In the past stamping dies have in principle been designed by rules of thumb and intuition. As the sheet metals in the vehicle industry have got increased mechanical properties in recent years the demands on the stamping dies have increased. For instance increase in stiffness is desirable in order to better control spring-back. The most simple way to satisfy this new demand would be to make the stamping dies even more heavy in order to be able to handle the new sheet metals. Since there are restrictions of the weight of the stamping dies in the stamping machines and since the overhead cranes usually have reached the limit of what they can handle, this is not a desirable solution. Another approach, in order to increase the stiffness without increasing the weight is to use topology optimization. Recently in a master thesis at Volvo Car Corporation a conceptual design of a stamping die has been done by topology optimization. In that work no consideration is taken to the fact that the stamping die is casted. Casting implies that residual stresses possibly are produced during the solidification and cooling process. The residual stresses might affect the fatigue life and the risk of failure of the stamping die.
In this work the residual stress state after casting is analyzed for the original stamping die as well as the optimized stamping die from the master thesis discussed above. The analyses are performed using an uncoupled approach, where one thermal analysis is followed by a quasi-static elasto-plastic analysis. The thermal analysis simulates the solidification and cooling during the casting process, while the quasi-static elasto-plastic analysis uses the temperature history, obtained from the thermal analysis, in order to build up residual stresses. The thermal analysis includes the release of latent heat. Furthermore, the material properties included in the heat equation (density, conductivity, specific heat) are given as temperature dependent properties for the mould as well as the casting. In the quasi-static elasto-plastic analysis the plasticity is described by the von Mises yield surface in combination with isotropic hardening and the mechanical properties (thermal expansion coefficient, Young's modulus, yield stress, hardening parameter, Poisson's ratio) are given as temperature dependent properties. The simulations show high levels of residual stresses.
Place, publisher, year, edition, pages
Olofström: Industriellt utvecklingscentrum i Olofström AB , 2008. 765-776 p.
IdentifiersURN: urn:nbn:se:liu:diva-72348ISBN: 978-91-633-2948-7OAI: oai:DiVA.org:liu-72348DiVA: diva2:459253
IDDRG 2008, Best in class stamping, 16-18 June 2008, Olofström, Sweden