Optimized Polymer-Based Sheet Metal Forming Dies: Leveraging Generative Design and Fused Deposition Modeling 3D Printing for Cost-Effective Manufacturing
摘要
This study explores the development of polymer-based sheet metal forming dies using fused deposition modeling 3D printing technology, utilizing acrylonitrile butadiene styrene (ABS) material. Generative design techniques in Autodesk Fusion 360 were employed to optimize die geometries, reducing material usage while maintaining structural integrity. Finite element analysis simulations were conducted to evaluate the mechanical performance of the ABS dies under operational conditions. The simulations indicated that the top die exhibited a Von Mises stress range from 0.069 to 8.684 MPa, with a maximum displacement of 0.215 mm, while the bottom die recorded a Von Mises stress range from 7.177 × 10−4 to 5.743 MPa, with maximum displacement of 0.029 mm, confirming the structural robustness of the printed dies. Experimental forming trials were conducted using sheet metals such as galvanized iron, aluminum, and copper under a nominal forming force of 1000 N. The results demonstrated that the 3D-printed dies successfully formed sheet metal without defects, achieving precise geometries while maintaining dimensional accuracy. The generative design approach significantly reduced die weight and material consumption, enhancing cost-effectiveness. Compared to traditional machining or casting methods, this technique resulted in reduced lead times and production costs, making it ideal for small-batch industries requiring on-demand and flexible manufacturing solutions. These findings highlight the potential of integrating generative design with additive manufacturing to develop lightweight, durable, and cost-efficient forming dies. Future work could explore the inclusion of metal reinforcements or hybrid material compositions to enhance the structural and thermal performance of polymer-based forming dies for high-stress applications.