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Journal of the Korean Society of Manufacturing Technology Engineers 22:6 (2013) 1018~1024

http://dx.doi.org/10.7735/ksmte.2013.22.6.1018 ISSN 2233-6036

Technical Papers

Addendum surface modeling of draw mold for automotive press panel forming

Jeong Yeon-chana*

Addendum Surface Modeling in Draw Die Design for Stamping Automotive Panels
Yunchan Chunga*
a
Dept. of Mechanical System Design Engineering, Seoul Tech., Gongreung-ro 232, Nowon-gu, Seoul, Republic of Korea

ARTICLE INFO ABSTRACT

Article history: In the process of draw die design for stamping automotive press panels, the addendum
Received 28 October 2013
surfaces generated in metal forming simulation software cannot be used in downstream
Revised 25 November 2013
processes such as machining and making draw dies because simulation tools use
Accepted 8 December 2013
simple discrete models for the surface geometry. The downstream processes require
more precise and continuous geometric models such as NURBS surfaces. Generally,
Keywords:
Addendum surface automotive die engineers manually regenerate
the addendum surface geometry using the discrete model. This paper presents an
Parametric modeling
Curvature estimation
automated geometric modeling process for generating addendum surfaces using draft
surface models. The design parameters of the section curve for the addendum
Draw die
surfaces are extracted automatically from the draft geometry. Using the extracted design
Stamping
parameters, smooth addendum surfaces are generated automatically as NURBS
Automotive press panel
surfaces. The generated surfaces are G1 continuous with the part surface and the
binder surface, and can be used in downstream processes.

1. Introduction These are hostile shapes. The binder side holds the initial plate for press forming.

plays a role, and the addendum surface is a curved surface that connects the product surface and

This paper examines the addendum of an automobile draw die . the binder surface and enables the drawing process in press molding. Automotive press panels

We propose a method for modeling faces. Draw Mold for Automotive Body Panels generally have complex and uneven shapes, making it difficult to obtain consistent forming force

It is responsible for the drawing process in the forming process . de on the mold surface during the drawing process. The addendum side is the enemy

Since the rowing process involves dragging a flat material into a mold to form it, it is necessary to It is a shape added to the mold surface to obtain optimal forming force [3-5].

properly control the forming force to prevent defects such as fractures and wrinkles. The undum The mold surface design of the automobile draw die is implemented through forming simulation.

curved surface of the draw mold is formed during the drawing process. It is carried out in an erroneous way. Fig. As shown in Figure 2, a shape model is created by

It is an important factor that affects the control of forming force [1,2]. changing design variables, and forming simulation is performed with the shape model.

The mold surface of the draw mold for automobile panel molding is shown in Fig. As seen in 1 do. If the simulation results are not satisfactory, reconsider the design variables.

Create a new shape model and repeat the simulation. Modification of design variables and
It is divided into part face, binder face, addendum face, etc.
It becomes like that. The binder side and the addendum side are additional surfaces that enable the forming of the panel. geometry until forming simulation results are satisfactory.

* Corresponding author. Tel.: +82-2-970-6395

Fax: +82-2-976-5173

E-mail address: ychung@seoultech.ac.kr (Yunchan Chung).

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Modeling is repeated [6]. It is an image that projects stripes so that it can be seen. In the picture, you can see that the continuity of

In many cases, the curved surface model used in forming simulation cannot be used as the final the curved surface is very poor. Additionally, characteristic curves such as round or fillet surface and ruled

shape information of the mold. The curved surface used in forming simulation has low precision, lacks surface are distinguished.

continuity, or has special design and manufacturing characteristics. You can see that it was created as one connected face. As a result

This is because it does not reflect the feature . Used in molding simulation Based on the curved surface model created during the furnace molding simulation process, a new curved

Since the curved surface is mainly a polyhedral curved surface model in the form of a mesh, the precision surface of suitable quality for post-processing must be created [9].

There is a limit to Parametric surfaces are also connected to adjacent surfaces. In the general automobile mold development process, CAD software tools are used to model the

There are many cases where tangential continuation is not satisfied. And one curved surface of the mold surface for post-processing . Recent CAD tools utilize various techniques such

Since it is often created as a large curved surface, it is difficult to find the design or manufacturing feature as parametric modeling.

shape and it is impossible to manipulate the feature shape unit. It is very convenient to use [10]. However, the addendum surface of the automobile mold

Curved surfaces created with AutoForm-DieDesigner [7] and PAM-Diemaker [8], which are Because its shape is complex, a lot of manual work is required even when using the latest CAD tools.

representative commercial tools used for mold surface design, are also difficult to use in post-processes Since the curved surface model verified as optimal design through forming simulation is usually a mesh

such as cutting processing. This is because the curved surface is created with a quality suitable for model, the design variables of the addendum surface, etc.

forming simulation. Fig. 3 is It also has to be inferred manually. The design variables of the addendum surface were secured.

Let's look at the quality of the addendum surface created in AutoForm-DieDesigner. Many labors are required to create the smooth curved surface required in mold production.

It takes energy and time.

Research related to the design of automobile draw molds largely involves mold geometry models.

It can be categorized into ring automation [11] and mold design optimization. mold shape

In delling automation research, the addendum surface or the entire mold surface is divided into several sections.

Methods for modeling with system variables have been proposed. Schenk and Debray et al.

Models the addendum surface as a parameter and determines the optimal value through forming simulation.

A method of optimization was proposed [3,4,9]. In these studies, the design variables were

Fig. 1 Components of a die face

(a) overall view

(b) magnified view

Fig. 3 An example of the addendum surfaces from a commercial

Fig. 2 Typical process of the die face design tool

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Model the cross section of the addendum surface along the outer boundary of the melt product surface. And at that point, if the second-order differential relationship such as equation (3) is satisfied,

Create an addendum curved surface by smoothly connecting multiple cross sections. Chi et al. used a It satisfies the G2 continuity condition , commonly called curvature continuity .

physical model to create a smooth addendum surface.

ÿ ÿ
proposed [12]. There has been no research suggesting a method to newly model a sophisticated addendum ÿÿÿÿÿÿÿ ÿÿÿÿÿÿ ÿÿÿÿÿÿÿÿ ÿÿÿÿÿÿ (3)
curve based on a mesh model that is the result of optimal design.

It was. When two curved surfaces are adjacent, the above conditions must be satisfied by following the curve

In this study, the results were obtained by repeating curved modeling and forming simulation. on the curved surface that crosses the adjacent boundary [13].

is a sophisticated design that can be used in subsequent processes using the optimal design shape model. In this study, by combining the opinions of mold design engineers, the addendum curved surface

We propose a method for modeling an addendum curved surface. Expressed as a mesh

The design variables of the cross section for are shown in Fig. It is defined as 4. Fig. As shown in Figure

The design variables of the addendum surface are extracted from the zone shape model through intersection
4, the design variables are six radii of arcs (Part, CB1, CB2, Bar1, Bar2, Die) , five angles (CB angle, CB

curve calculation. Create a cross-sectional curve of a new addendum surface using the extracted design variables
slope, Bar angle, Bar slope, Wall angle), and four lengths (Part plus, CB height, CB width, Bar height)

do. Multiple cross-section curves, product surface boundary curves, and binder surface boundaries
variables.

Create a smooth addendum surface using curves. In Chapter 2, the entire

This explains how to create an additive curved surface. The implementation of the proposed method and The cross-section curve created with defined design variables consists of a minimum of 1 and a

its results are described in Section 3, and conclusions are presented in Section 4.
maximum of 6 circular arcs. The first arc (part) is connected to the product surface by a tangential line.

Circular arcs that are adjacent to each other are also connected by tangents. last circle

2. Creation of addendum surface The die is in direct contact with the binder surface.

Design variables of addendum surfaces used in forming simulation and this study

2.1 Requirements The design variables defined in may be different. Even when the same design variables are used, the

Through interviews with mold design engineers and analysis of existing work, we found that there were original design variables are accurately maintained by simplifying with mesh surfaces, etc.

several constraints to addendum surface modeling. Molding Simulation It is difficult to restore. Ultimately, design variables must be estimated from the shape model.

The constraints for addendum surface modeling using the optimal design shape obtained through

simulation are as follows.

1) Design variables can be modified by the user. 2.2 Overall procedure

2) The curved surface is divided into several small feature surfaces. In order to satisfy the constraints described in the previous section, this study proposes

Negative control is possible. The overall procedure of addendum surface modeling is shown in Fig. Same as 5. The first step is to

3) Create continuity [13] of G1 or higher with two adjacent surfaces (product side, binder side). extract design variables through cross-sectional analysis of the existing addendum curved surface.

It's enough. It happens. At this time, the extracted design variables can be modified by the user. In the second step,

4) The inside of the addendum curve satisfies continuity of G1 or higher. cross-section curves corresponding to the design variables are created. section

A curve is composed of a combination of straight lines and arcs. In the third step, only

At this time, G1 continuity expresses the smoothness of a curve or curved surface. Create a guide curve connecting surface curves. Cross-sectional curve in the last step

is a term. If the two endpoints of two adjacent curves f(t) and g(t) coincide as shown in equation (1), the G0

continuity condition is satisfied at that point.

f(1) = g (0) (1)

Also, at that point, if the direction of the first differentiation result is the same as in equation (2), G1

Continuity conditions are satisfied. G1 continuity is also called tangential continuity. ceremony

, ÿÿÿ is the unit tangent vector of the meeting point.

ÿÿÿÿÿÿÿ ÿÿÿÿÿÿÿÿÿÿÿÿÿÿ ÿÿÿÿÿÿÿ ÿÿÿ (2)

Fig. 4 Design parameters for the section curve

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Create the final addendum curve using lines and guide curves. Feature curved surface In , the intersection curve was obtained as a point series curve. Fig. 6 is an example of an intersection curve

In order to create a division, a curved surface is created for each square piece of the curved network formed obtained from a mesh model.

by the section curve and guide curve. At this time, the adjacent product side or binder

Creates a curved surface that satisfies G1 continuity with the surface . 2.4 Design variable extraction

It is not simple to extract the cross-sectional design variables of the addendum from the obtained

2.3 Create intersection curve intersection curve. To extract cross-sectional design variables from the intersection curve, this study used a

To extract design variables from the existing addendum curve, the existing Fig. method of extracting arc sections from the intersection curve.

4 Design parameters for the section curve Addendum curved surface and plane Fig. As shown in Figure 6, after calculating the curvature at each point of the intersection curve, the section

Analyze the intersection curve of . The plane to generate the intersection curve is parallel to the operating with constant curvature was separated into one unit. By approximating the arc corresponding to the

direction of the mold. And it is perpendicular to the boundary curve of the product projected on a plane separated section and then finding the tangent line connecting the arc, you can finally obtain a curve

perpendicular to the direction of mold operation. The location is defined on the product's boundary curve. composed of the arc and line segment. Obtained arcs and line segments

The user determines the position of the required cross section by examining the characteristics of the entire When analyzing the curve consisting of , Fig. A design variable of 4 can be obtained.

addendum surface. Once in position, the three axes that define the intersecting plane are: The fitting section of the arc for calculating the radius of curvature is variable.

This is determined by equations (4), (5), and (6) . The circle is approximated in the maximum approximation interval that satisfies the standard approximation error. far

Approximate a circle with the minimum points around that point and calculate the approximation error.
ÿÿ ÿÿ ÿÿ ÿÿ

ÿÿ ÿ× ÿÿ (4) all. If the approximation error is smaller than the standard error, the approximation interval is slightly
ÿÿ ÿÿÿ ÿ ×

expanded and recalculated. The approximation section continues to be expanded, and expansion is stopped

ÿÿ ÿÿ

when the approximation error exceeds the standard. This method requires a lot of computer calculations
ÿÿ ÿ (5)
because the approximation interval is uncertain and the calculation is done by sequentially increasing the

ÿÿ ÿÿ ÿÿ

interval. However, with recent computer performance, there is no major difficulty. Based on
ÿÿ ÿ×ÿ (6)
The optimal approximation error to be used was 0.01 .

ÿÿ ÿÿ
The method proposed by Kasa [14,15] was used to approximate a certain string of points into a circle .
The unit vector in Eq. ÿ is the operating direction of the press mold, ÿ is a plane

The general approximation of a circle optimizes the square of the error.

This is the tangent vector of the product boundary curve at this location. The direction of the product
ÿÿ
Use digestible standards. In other words, when N points are given, equation (7) is given.
boundary curve is
A counterclockwise direction was assumed when viewed from the ÿ-axis.

Find the radius R of the circle .

The intersection curve of a plane and a curved surface is easily obtained through general geometric operations.

You can. Especially when the curved surface is expressed with simple information such as a mesh,
ÿ
The calculation of the intersection curve of a surface and a curved surface is performed stably. this study
ÿÿÿ ÿÿÿÿ (7)
minÿÿ

,
At this time ,

ÿÿÿ ÿÿÿÿ are the x, y coordinate values of the ith point . N is the number of points to approximate

Fig. 5 Overall modeling process for the addendum surfaces Fig. 6 An example of the intersection curve and the curvatures

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and is greater than or equal to 3. And (a, b) are the coordinates of the center point of the approximated circle When created, a curve different from the original intersection curve is obtained. Product side and bar

It is a value. However, equation (4) is difficult to solve using analytical methods. This is because continuity of the surface is considered and a limited number of design variables are used. In

Kasa proposed a modified least squares method as shown in equation (8) . this study, the user creates a cross-section curve with design variables.

It was possible to modify the design variables while looking at the . The user modifies the value of the design

ÿ
variable by considering the surrounding shape or modifies the value of a specific design variable based on
ÿ
ÿÿÿ ÿÿ ÿ ÿÿ (8)
minÿÿ experience knowledge.

Fig. (a) in 7 is an example of a cross-section curve created with design variables. In the figure, the section

The method presented by Kasa can obtain a solution through an analytical method, and the results were with dense dots is a circular arc, and the section without dots is a straight line connecting the arcs.

sufficient to be used in this study. It approximates a circle

am. Fig. The example shown in 7 is Fig. The theory extracted from the intersection curve shown in 6

A good methodology can be found in the study by Rusu et al . [16]. This is the result of modifying the Part Plus length to 0.5 and the Die radius to 7 in the system variable

values . Fig. In (b) of 7, place it above the left starting point.

2.5 Create cross-section curve The curve is a regenerated cross-sectional curve.

Create a cross-section curve consisting of line segments and arcs by inputting design variables

do. When creating a cross-section curve, the starting point is placed on the boundary curve of the product surface.
2.6 Creating guide curves

The tangent of the starting point coincides with the tangent of the product surface. The end point lies on the
The guide curve is shown in Fig. As shown in Figure 8, it is a curve connecting cross-section curves. The guide

boundary curve of the binder surface and its tangent coincides with the tangent of the binder surface. Like this curve cv-P connecting the starting point of the cross-section curve is the boundary curve of the product and the end

Both ends of the curve created create G1 continuity on the product side and the binder side. The curve cv-B connecting the points is the binder boundary curve. In the figure, guide curve cv-1 and guide

It's enough. And the interior also satisfies G1 continuity. curve cv-2 are properties of guide curve cv-P , which is the product boundary curve.

The sequence for creating a cross-section curve that satisfies the constraints is as follows: It is created by inheriting . Guide curve cv-1 and cv-2 are created by converting the guide curve cv-P to scale

all. Using the tangent condition, Fig. Create the arc part and die shown in 4 first. Then, create arc Bar1 using and translation . Excluding guide curves cv-1 and cv-2

the distance variable and then create Bar2 using the angle variable . Again, create CB1 and CB2 using the One other guide curve is the tangent vector of guide curve cv-P and guide curve cv-B.

distance variable and angle variable . Blend the data and use it as the tangent vector for each vertex. In this study, a guide curve was generated

using a cubic B-spline curve to ensure G1 continuity.

Redraw the cross-section curve using the design variables extracted using the method described in the previous section.

2.7 Surface creation

Given a curved network of section curves and guide curves, a curved surface can be created. However,

in the case of the addendum curved surface, the product surface or binder surface and G1 or higher

(a)

(b)

Fig. 7 An example of the re-created section curve: (a) re-created

section curve, (b) overlapped view with the intersection
curve Fig. 8 Guide curve construction

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continuity must be satisfied. In this study, since the cross-section curves and guide curves that form the 4. Conclusion

curve network satisfy the surrounding curves and G1 , adjacent curves

The method of creating a curved surface that satisfies continuity is a well-established geometric principle.
In this study, gold in draw molds for producing automotive press panels was studied.

Jada. In this study, a curved network was used to determine tangential continuity with surrounding curved surfaces.
A modeling method for the addendum curve that constitutes the form surface was proposed. The proposed

A NURBS curve [17] that satisfies was created. More details can be found in other existing studies on
method extracts the design variables of the addendum cross section from the mesh model modeled

generating addendum surfaces [12,18].

during the press forming analysis process. Using the extracted design variables, a new cross-section

curve and guide curve of the addendum are created, and then a smooth curved surface is finally created.

3. Implementation results As a result of implementing and testing the proposed method, it was found that the proposed method can

be used to develop modeling automation tools. And it was found that the implemented tool was useful.

The method proposed in this study was implemented using the commercial CAD system UG/OPEN

API and C++ . The intersection curve described in Section 2.3 is The significance of this study is to extract design variables from an existing model and then regenerate

It was implemented using the existing functions of the API . The extraction of design variables, generation the addendum surface. Much research so far has been

of cross-section curves, and guide curves described in Sections 2.4, 2.5, and 2.6 were implemented Automatically designs mold surfaces such as bonuses. However, in the case of automotive panel molds,

directly in C++ . Surface creation described in Section 2.7 uses API functions. the design is done through a lot of trial and error, so users

It was implemented. The developed program runs on Siemens NX. A structure that can reflect the know-how is needed. In this study, design variables are extracted from

Fig. 9 is Fig. This is an addendum curve newly created in a program implemented with the curve automatically designed shapes. Use extracted design variables

shown in 3 as input. It can be seen that the projected stripes continue smoothly at the curved surface You can create a new curved surface by changing it yourself.

boundary, creating a smooth curved surface that satisfies G1 continuity. Tangents at the boundaries of

curved surfaces through surface analysis 5. Future research directions

It was confirmed that the directions match. It was also confirmed that the direction of the tangent line was

consistent at the connection between the product surface and the binder surface.
As a future task, changing design variables and curved surfaces should be more intuitive so that users

As a result of investigating the working time of mold design practitioners, using the implemented
can easily modify them. The method presented in this study is not an automatic design, but a method to

program, the addendum curve creation work, which previously took an average of 20 man-hours, could be
increase user productivity, and is not an automatic design method .

completed in 5 man-hours. And the created curved surface could be used in post-processes such as mold
This is because karma is a repetitive process. And a method to control the curved surface while

production.
maintaining the continuity and overall outline of the created addendum curved surface.

The development results show that the method proposed in this study can be used to model existing shape models.
If provided, it can be used for repetitive fine tuning of the curved surface to improve formability.

It is useful when recreating a precise and smooth addendum surface using

It will be a blessing.

I could see that it was The developed modeling tool automatically

The binder curved surface also adopts a concept similar to the method presented in this study.

Extracts and is required when the user creates a new addendum surface.
You will be able to model it. Used for forming simulation calculations of sheet metal

Provides guidance. And the addendum curved surface created by this method can be fully used in mold
High-quality binder curved surface to be used in post-processing using the binder curved surface

production.
You will be able to create . For binder surfaces, from a shape modeling perspective,

Clarifying design variables is also an important research task.

review

This research was partially supported by academic research funds from Seoul National University of Science and Technology.

It has been done.

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Fig. 9 Re-created addendum surfaces

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