Comparison of Optimum and Square Blanks Using the Sensitivity Approach

Abstract—This paper studies the modified sensitivity analysis applied into an elastic-plastic finite element analysis of a 3D blank design in sheet metal forming. Originally the sensitivity method has successfully been applied to several arbitrary shapes. In the present paper the sensitivity coefficients are not considered constant during the analysis. The presented approach computes the new coefficients from the two last iterations. This method can produce an initial blank boundary shape that has any arbitrary flange shape. A cup with uniform flange has been studied in detail and results show a faster solution convergence than the published sensitivity method. Experimental tests were conducted to compare with the numerical simulations. The optimum blank shape obtained from the numerical simulations was used during the experimental trials. The results of experimental tests for both square and optimum blank are presented here. Index Terms— Finite element method, modified sensitivity analysis, optimum blank, sheet metal forming.