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Optimization of Tool/Workpiece Orientation in Designing Die-Face of Automobile Outer Panels

A procedure has been developed to optimize the product's tipping position, that is the relative orientation of the product surface with respect to the punch direction in a die, in designing a die-face for the manufacture of automobile outer panels. The two design requirements that are considered in optimizing the tipping position are: to satisfy that all points on the product have the most uniform drawing depths and to guarantee that the user-specified area on the product should contact initially with the binder wrap prior to other regions. The problem to solve when satisfying the design requirements described above is analogous to the flatness calculation problem in the area of metrology if some constraints can be imposed. Thus the problem can be solved by the simulated annealing method, which is one of the optimization methods. The developed procedure was applied to an actual die-face design and the results showed that the procedure was useful through the distribution diagram of the drawing depths.