A Numerical Approach to Improve Thickness Distribution of Hemispherical Part in Gas Pressure Forming through Reverse Pre-Bulging on Simple Stepwise Geometry Tool
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초록
Excessive thickness reduction at the center of a sheet is a major drawback when producing a hemispherical part through gas pressure forming. In this paper, a two-stage gas pressure forming process based on reverse blowing with a simple geometry die is proposed to produce a part with uniform thickness distribution. The preform die, which is a key component and used in the first stage of the process, is shaped with only straight lines and fillets for convenience in its design and manufacturing. This is defined with seven geometric parameters and optimized values are obtained through direct optimization with the objective of maximizing the minimum value of thickness of formed part. In this numerical study, the commercial software ANSYS Mechanical Products 2022 R1 is used and the reliability of the simulation model is verified by comparing with results from the previous study which investigated the deformation of pure lead sheet. As a result, the thickness distribution was more improved than existing methods as the minimum thickness additionally increased by 11.1%. The results show that the proposed method contributes to better production of the hemispherical part by improving the formability of material.
Abstract
Excessive thickness reduction at the center of a sheet is a major drawback when producing a hemispherical part through gas pressure forming. In this paper, a two-stage gas pressure forming process based on reverse blowing with a simple geometry die is proposed to produce a part with uniform thickness distribution. The preform die, which is a key component and used in the first stage of the process, is shaped with only straight lines and fillets for convenience in its design and manufacturing. This is defined with seven geometric parameters and optimized values are obtained through direct optimization with the objective of maximizing the minimum value of thickness of formed part. In this numerical study, the commercial software ANSYS Mechanical Products 2022 R1 is used and the reliability of the simulation model is verified by comparing with results from the previous study which investigated the deformation of pure lead sheet. As a result, the thickness distribution was more improved than existing methods as the minimum thickness additionally increased by 11.1%. The results show that the proposed method contributes to better production of the hemispherical part by improving the formability of material.