Data-Driven Compensation for Bulk Formed Parts Based on Material Point Tracking

Abstract

Currently, common inefficient trial-and-error procedures are used in designing bulk forming dies. Numerous iterations, consisting of numerical simulations and subsequent real tests, are needed to achieve accurate parts. During the compensation cycles, manual redesign in CAD environments is necessary to transform discrete data into parametric descriptions causing approximation errors. Automation of these surface reconstruction processes is barely possible. To address these issues, different data-driven numerical strategies have been deduced based on either displacement or force. In this work, a material point tracking method in forming simulation between die and part geometry is presented. Based on this, enhanced displacement-based and stress-based methods for compensation of bulk forming parts are compared. The convergence behavior of both methods is analyzed with respect to the compensation factor. Finally, the material point tracking approach is validated and verified by compensating a two-dimensional bulk-formed component.