Structural Modeling of Profiled Edge Laminate (PEL) Tools Using the Finite Element Method

Abstract

Profiled Edge Laminate (PEL) tooling is a rapid tooling method that uses a stacked array of vertically orientated thick laminae with profiled and beveled top edges to provide the desired surface shape for part forming or molding. Since this method is being developed for commercial use, there is a need to be able to predict the response of PEL tools to both structural and thermal loads encountered during a manufacturing process. In this paper, a general approach for structural modeling of PEL tools is developed using the Finite Element Method (FEM). To validate this method, an experimental case study is performed. Specifically, a PEL test tool is subjected to two-dimensional structural loading to simulate a sheet metal hydroforming process, while tool displacements and strains are recorded. The experimental results are compared to those obtained using the FEM modeling approach, conclusions are drawn about its effectiveness, and more advanced modeling work is proposed.