Abstract:

The goal of the structural design of a stamping die is to obtain the optimal structural configuration and the corresponding size parameters while considering both structural performance and die weight， which is difficult to achieve with a single topology optimization process. Therefore， a design method combining topology and size optimization for stamping die structure is proposed in this paper. The method avoids the complicated load mapping calculation step by adopting the node-to-node load mapping strategy， thus directly transferring the load distribution on the contact surface to the loading step in the static model. The relaxation coefficients of the structural performance in the topology optimization model are determined by the given performance evaluation index and the corresponding selection strategy so that the mechanical properties of the topology optimized dies are not weaker than those of the initial design while reducing the weight as much as possible. Finally， according to the optimal structural configuration obtained from the topology optimization， the corresponding structural parameters are determined by the multiple surrogate models-based size optimization method. The method is successfully applied to the optimal design of stamping dies for automotive structural components and its effectiveness is verified by comparing the results of the initial design， topology-optimized design， and topology size joint optimization design.

Key words: stamping die design, load mapping, topology optimization, multiple surrogate models