Optimization of Blanks for Sheet Metal Forming

The objective of this paper is to formulate a systematic method to optimize the input blank size in sheet metal forming operation. Large deformation, large strain, plastic analysis is done using a commercial explicit solver for an automobile cab component. Initial analysis is done for the existing production condition of sheet metal dimensions and binder load. Formability-limiting diagram (FLD) and percentage reduction in thickness are taken as the objective function and the variables are blank contour dimensions and binder force. Varying the binder load and sheet metal dimensions, optimal output is achieved after several iterations. Final sheet metal blank dimension results in cost savings and reduction in scrap percentage. The results of FEA are verified experimentally by circular grid analysis.