Effectiveness of digital image correlation method in evaluation of design of 3D-printed plastic tools for sheet metal forming

Researchers at Toyohashi University of Technology, in collaboration with the National Institute of Technology, Nagano College, and the Rajamangala University of Technology Isan, have evaluated the deformation behavior of tools and sheet using a digital image correlation method in V-bending of sheet metals with plastic tools manufactured by a 3D printer.

This method clarifies the deformation of the plastic tools during thin sheet metal bending, opening possibilities for design of plastic tools for stamping sheet metal products, particularly in small-lot production.

The team, led by Associate Professor Yohei Abe, combined the digital image correlation method with the observation by a digital camera, proposed by Assistant Professor Naotaka Nakamura. Two different dimensions, designed with the same tool geometry, were evaluated for their effects on the deformation behaviors of a 3D-printed PLA punch, die, and sheet. The measurements revealed the presence of large compressive strain at the center of the punch tip and on the corners of the die.

The study successfully measured the deformation behaviors of plastic tools in stamping. These findings suggest potential advancements in the design of plastic tools for industry. The team plans to combine this method with finite element simulation to accelerate smart tool design.

Naotaka Nakamura, Yuri Hata, Witthaya Daodon, Daiki Ikeda, Nozomu Adachi, Yoshikazu Todaka, and Yohei Abe, "Design of Tool Shape and Evaluation of Deformation Behavior by Digital Image Correlation Method in V-Bending of Sheet Metal Using Plastic Tools Manufactured by 3D Printer", Materials, 2025, Vol. 18, No. 3, 608. DOI: 10.3390/ma18030608