Sheet metal tools design

Abstract

Whatever the manufacturing process being used, a correct dimensioning is essential for the development of feasible and reliable tools. Thus, attention must be paid during the tool design for successful use. Generally, tool dimensioning should consider the fulfilment of geometric, mechanical loading and thermal requirements of the process where they are to be used. A sheet metal tool should be designed to mimic the operation of conventional tools. Thus, it must consider both the correct geometry of the target part as well as the possible manufacturing process awarenesses as material shrinkage, demoulding possibilities and clamping and positioning systems. Besides, the geometric possibilities for the sheet metal parts must be considered, exploring not only the potential of ISF processes but also other flexible forming techniques. From the mechanical point of view, the tool development should consider its operation loading in the selection of material and thicknesses, including the possible use of supports and reinforcements. The thermal behaviour of the parts may also influence the tool design. Further, the understanding of thermal behaviour of tools helps to validate their use and defining process cycle time.