Modeling Buckled Developable Surfaces for Binder Design in Sheet Metal Forming

Friday, February 20, 2004 - 1:25pm - 3:00pm
Vincent 570
William Frey (General Motors Corporation)
In the first stage of sheet metal stamping, a binder ring, an annular surface surrounding the die cavity, clamps down on the flat blank, bending it to a developable binder wrap surface which may be smooth or buckled. Buckles generally appear in the binder wrap when the binder ring does not lie on a smooth developable surface that spans the die cavity. However, sometimes buckles can improve the formability of the stamped part, so the ability to design buckled developable surfaces becomes desirable. Designing buckled developable surfaces requires geometric modeling of creases and other singularities in the interior of a flat sheet. In this talk, I will review the properties of such surfaces, describe a method of approximating buckled binder wrap surfaces by developable three-dimensional triangulations and discuss the insights gained from specific examples.