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In this study, we analyzed the internal influence of the number of stamping on die wear through equivalent continuous stamping simulation and explored the wear state of the die at different stages before the die loses dimensional accuracy. First, the largest wear part of the mold was studied through simulation and experiment. The results showed tha...
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Citations
... For this reason, numerous existing efforts use the surface roughness and friction coefficients to identify and quantify the mold wear state. For instance, the mold wear state at different stages was identified through the mold surface roughness obtained from the equivalent continuous simulation in U-shaped stamping [12]. Wu et al. investigated the effects of ultrasonic vibration on mold wear, and the friction coefficients between mold and blank were used as a quantitative indicator of wear [13]. ...
Existing various constructed models of stamping provide great support to develop the forming quality improvement and energy-saving strategies. However, the immutable model cannot reflect the actual states of the process as the wear of the mold goes, and the inaccuracy model will lead to the failure of the strategies. To solve this problem, a Digital Twin-driven modeling method considering mold wear for stamping process was proposed in this paper. The model of punch force and forming quality considering the coefficients that will vary with the status of mold wear was first built in the virtual space. The real-time punch force was acquired and input to the virtual space for monitoring the mold wear, and then compared with the punch force obtained by the Digital Twin model. If the difference of punch force is greater than the threshold, the friction coefficients update starts by PSO-DE algorithm. To validate the effectiveness, the method was applied in the process to form a clutch shell, and results show that the accuracy of the updated Digital Twin model is improved by 61.97% compared to the initial model in the case of mold wear. Optimization results in the application show a 14.35% reduction in the maximum thinning ratio of the stamping part and an 8.9% reduction in the process energy. The Digital Twin-driven modeling assists in quality improvement and energy consumption reduction in sheet metal forming.
The surface texture and roughness parameters of the workpiece after milling have a greater impact on the performance of the workpiece, so the analysis of the milling topography is particularly important. Firstly, the edge line of the ball end milling cutter was modeled. According to the movement law of the milling process, a complete set of milling topography simulation model was established, and a new influencing factor phase difference is proposed. In addition to the conventional cutting parameters, the model also considers the phase difference and tool inclination. Secondly, through the topography analysis and the calculation of the height of the convex peak Hmax, the comparison with the experiment was carried out to further verify the accuracy of the model. Finally, the point cloud data obtained from the topography simulation is processed, the roughness Sa is calculated according to the least square method. and the influence of the phase difference Δφ and the tool inclination β on the milling topography, surface texture and roughness Sa are respectively analyzed. The conclusions obtained provide guidance and reference for industrial parts designers who have specific texture requirements.
In the field of mold manufacturing, the wear resistance of the mold is a key factor affecting the life of the mold. In order to extend the life of the mold, most scholars have invested a lot of research on the surface texture of the mold. This article mainly analyzes the influence of the texture angle of different milling topography on the wear resistance of the mold. First, we studied the formation process of the milling topography, and distinguished the quadrilateral pit topography and the hexagonal pit topography by defining the texture angle. Secondly, we carried out a wear simulation analysis on the slider with a texture angle, and studied the influence of different topography on the wear depth and stress distribution. Finally, with the help of friction and wear experiments, the wear amount of the slider with different texture angles is tested, and the relationship between the texture angle, the wear quality and the friction coefficient is analyzed. The conclusions obtained provide an effective reference for industrial designers to prepare wear-resistant molds.
