A New Method For Advanced Virtual Design Of Stamping Tools For Automotive Industry: Application To Nodular Cast Iron EN‐GJS‐600‐3

14th International Conference on Material Forming ESAFORM, Queens Univ, Belfast, NORTH IRELAND, APR 27‐29, 2011International audienceThis contribution presents an approach combining the stamping numerical processing simulations and structure analysis in order to improve the design for optimizing the tool fatigue life. The method consists in simulating the stamping process via AutoForm (R) (or any FEM Code) by considering the tool as a perfect rigid body. The estimated contact pressure is then used as boundary condition for FEM structure loading analysis. The result of this analysis is used for life prediction of the tool using S‐N fatigue curve. If the prescribed tool life requirements are not satisfied, then the critical region of the tool is redesigned and the whole simulation procedures are reactivated. This optimization method is applied for a cast iron EN‐GJS‐600‐3 as candidate stamping tool materiel. The room temperature fatigue S‐N curves of this alloy are established in laboratory under uniaxial push/pull cyclic experiments on cylindrical specimens under a load ratio of R (sigma(min)/sigma(max)) = ‐2