Structural design of stamping die of advanced high-strength steel part for automobile based on topology optimization with variable density method.

Advanced high-strength steel is widely used in automobile production and manufacturing, for its advantages of light weight, high strength, and good formability. Compared with common steel plate, higher forming forces are required during the stamping forming process of advanced high-strength steel plate due to its continuous strength improvement. The higher forming forces directly result in a sharp increase in the reactive force on the stamping die, which easily cause inevitable fatigue deformation and damage fracture. In view of the above problems, the stamping forming process of an advanced high-strength steel anti-collision beam part and the loading bearing condition of the stamping die were explored. On basis of the theory of topology optimization, the structure of the stamping die was optimized to obtain the qualified stamping parts and the lesser quality punch. A method based on the node contact force conversion was proposed, and the reactive force on the stamping die during the forming process was obtained to function as the load boundary condition of topology optimization. Geometric reconstruction of the stamping die was implemented referring to the topology optimization results. The final result reveals that the lightweight punch and the qualified stamping part without fatigue deformation can be efficiently achieved through topology optimization. [ABSTRACT FROM AUTHOR]