Determination of optimal blank holder force trajectories for segmented binders of step rectangle box using PID closed-loop FEM simulation.

Blank holder force (BHF) is one of the key parameters affecting the process of sheet metal stamping. Numerous researchers have demonstrated two primary failures (wrinkling and tearing) could be avoided if appropriate variable BHF profile was implemented during punch stroke. Several approaches are proposed to determinate optimal BHF by experiment or FEM simulation. In this study, new control objective was adopted based on the definition and analysis of BHF formability window. The PID controller was integrated into FEM code to conduct closed-loop forming simulation of step rectangle box, through which the optimal BHF trajectories were determined for each separated binder. The trajectories were verified on a multipoint variable BHF hydraulic press and showed good effect to avoid wrinkling and tearing. The proposed BHF determination approach in this paper can be applied to stamping parts of different geometry due to the application of new objective, which makes it a robust strategy. [ABSTRACT FROM AUTHOR]