3D Drawbead Design and Mesh Regeneration in ANSYS FORMING®

In ANSYS FORMING, we have developed innovative techniques for predicting drawbead forces and generating 3D drawbead geometry to streamline the drawbead design process, which is crucial for controlling material flow in stamping processes. These tools include a drawbead profile generator, a simulator, and a 3D drawbead generator. The profile generator creates custom drawbead profiles based on sectional design parameters, while the simulator estimates restraint and uplift forces through a strip drawing test. The 3D drawbead generator automatically creates 3D drawbead meshes from single or multiple drawbead profiles for both closed and open beads, enabling accurate material flow estimation in 3D high-fidelity stamping simulations. In addition, we introduce an innovative surface mesh regeneration method based on adaptive quadtree refinement to address issues of distorted or skewed initial meshes. This method intelligently refines regions with complex features or high gradients that require higher resolution, while discretizing smoother areas with coarser elements, optimizing computational resources without sacrificing precision. Our approach also preserves original boundaries, ensuring the fidelity of simulation results. These advancements, validated through real-world examples, significantly enhance the design capabilities and modeling performance of ANSYS FORMING in stamping simulations.