Topology optimization and lightweight design of stamping dies for forming automobile panels

Accurate prediction of deformation and stress distribution on stamping die components is critical to guarantee structure reliability and lightweight design. This work aims to propose a new method for predicting die structural behaviors and reducing total weight based on numerical simulation. Sheet metal forming simulation was firstly conducted to obtain the accurate forming contact force. The linear static structural analyses under different load conditions were performed to investigate the deformation and stress distribution of the die structure. Topology optimization was employed to realize the lightweight design on the premise of ensuring structural safety. According to the manufacturing techniques and initial optimization results, the die structure was redesigned to guarantee the manufacturability of the new structure. The proposed methodology has several advantages of decreasing model scale, precluding intricate contact condition settings as well as time saving. A long beam stamping die used for forming automobile panels was selected to validate the proposed methodology, and about 18% weight reduction was achieved.