This research paper presents a topology optimization study of a press tool consisting of a punch and a die, with the aim of optimizing the press tool topology to reduce material usage, and manufacturing time while maintaining necessary strength. The tools will be manufactured using additive manufacturing technology with Polylactic Acid (PLA) material. The Additive Manufacturing method can be used to make prototypes of press tools in the development stages. This method also allows us to make low-cost press tools for short production runs. The loads acting on the punch and die were calculated and a Finite Element Analysis was performed to simulate the tool’s behaviour under loading. The results from this analysis were used to conduct topology optimisation of the press tools. Another finite element analysis was then used to validate the optimized design and to ensure that it met the necessary strength and factor of safety. The final optimized design was selected based on its ability to meet the minimum factor of safety of 4 while also achieving a significant reduction in material usage and weight. A manufacturability analysis was performed using Cura slicing software to ensure that the design could be fabricated using the additive manufacturing process. The results. showed that the optimized design could be manufactured with the additive manufacturing process. This confirmed the feasibility and effectiveness of the proposed optimization approach. This study demonstrates the potential of using topology optimization and additive manufacturing in the design and manufacture of press tools.
Keywords: Topology optimization, additive manufacturing, Press tools, Factor of Safety
This article belongs to Special Issue Conference International Conference on Innovative Concepts in Mechanical Engineering (ICICME – 2023)
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|Received||August 18, 2023|
|Accepted||September 12, 2023|
|Published||September 22, 2023|