Topology optimization of forming tools: pressure die in rotary draw bending process

The forming tools are conventionally manufactured from alloy steels. These tools can be designed to be light weight and cost effective without compromising performance characteristics. In this research, a fundamental forming tool (pressure die) of ‘rotary draw bending processes’ is topology optimized and 3D printed by using polymeric material. An accurate FE-simulation model of a rotary draw bending process is developed and topology optimization of the pressure die is carried out on the basis of contact stresses provided by FE-simulation results. The topology optimized pressure die is compared with its conventional metal made counter-part in terms of contact forces, contact normal stresses, effective area in-contact and cost performance index. This manuscript demonstrates that topology optimized lightweight 3D printed polymeric forming tools are a cost effective alternative to comparatively heavy alloy steels. This research contributes to widen the avenue of cost effective manufacturing by incorporating topology optimization regimes into existing production setups.