Citation Link: https://doi.org/10.1007/s00170-025-17265-1
Topology optimization of die geometry through identification of high pressure areas on die surface
Alternate Title
Topologieoptimierung der Werkzeuggeometrie durch Identifizierung von Hochdruckbereichen auf der Werkzeugoberfläche
Publication Type
Article
Subjects
Forming tools
Tube bending
Die design
Pressure transmission
DDC
620 Ingenieurwissenschaften und zugeordnete Tätigkeiten
Source
The International Journal of Advanced Manufacturing Technology (2025). - https://doi.org/10.1007/s00170-025-17265-1
Date Issued
2025
Abstract
In profile bending of tubes, FE-simulations have shown that the contact between tool (die) and metal tube manifests a unique contact pressure pattern at the tool surface. In this study, practical sensors are employed to determine the pressure transmission from tube onto tool surface. The physical measurements provided by sensors showed high agreement with the FE-simulation. It is demonstrated that the pressure exerted by the tube is not transmitted uniformly throughout the tool surface rather it is localized towards centre and fringes. This investigation opens up the possibility to design tools (forming dies) using topology optimization. The topology optimized geometry of a tool results in substantial material savings within the tool geometry. This research paper demonstrates that the identification of pressure pattern on the tool surface provides the basis to design tools with bare essential material within the tool geometry, hence stepping forward towards cost effective manufacturing of tools.
Description
This research paper is written within the context of project ‘Hybrid Tools’ supported by DAAD – Germany. The project results will be disseminated as open access publications. The project aims to incorporate cost effective production in existing industrial setups within Germany and abroad. The automotive industries (e.g., Mercedes Benz) can greatly benefit from the open access publications by incorporating the highlighted manufacturing strategies in their setups.
The authors are thankful to the institute of Forming Technology, UTS - Siegen for providing the resources to conduct this study.
The authors are thankful to the institute of Forming Technology, UTS - Siegen for providing the resources to conduct this study.
License
Creative Commons license
File(s)![Thumbnail Image]()
Loading...
Name
Topology_optimization_of_die_geometry.pdf
Size
1.7 MB
Format
Adobe PDF
Checksum
(MD5):a9c50b04e7f67ac699c421aed846ef86
Owning collection