Integration System for Optimum Blank Design of a Cylindrical Cup Drawing by Using the Control Point Updating Method

In this paper, a CAD/CAE/CAM integration system for optimum blank design of cylindrical cup drawing was proposed. Taguchi method was adopted to analyze the significance of design parameters. A 4-order Bezier curve was proposed to describe the blank profiles. The bound of optimum blank profile was obtained by using the uniform deformation method and energy method. The Golden section method was adopted to automatically update control points which control the shape and size of the blank. The FEM method was adopted to analyze the forming process precisely during the iteration procedure. An optimal blank design was obtained by using the proposed method. The maximum deviation of cup height was under 0.215 mm. The root mean square of the deviation of cup height was under 0.135 mm. The optimum blank was cut by using WEDM process and the NC code generated by the proposed integration system.