Multiobjective Optimization Method for Drawbead and Blank-Holder Force Design in Sheet Metal Forming Process

Authors

Abstract

Present study describes the approach of applying Multi-Objective optimization method to optimizing of sheet metal forming Die. In many studies, Finite element analysis and optimization technique have been integrated to solve the optimal process parameters of sheet metal forming by transforming multi-objective problem into a single-objective problem. This paper aims to minimize the objective functions of fracture and wrinkle simultaneously. Design variables are blank-holding force and draw-bead geometry. Response surface model has been used for design of experiment and finding relationships between variables and objective functions. In designing of experiments v-optimal design has been used which minimizes the average prediction error variance, to obtain accurate predictions. Forming Limit Curve has been used to define the objective functions. Finite element analysis applied for simulating the forming process. Proposed approach has been investigated on a drawing part and experimentally verified. The optimal design showed a good agreement with experimental species. It has been observed that proposed approach provides an effective solution to design of process parameters without a the ‘trial and error’ procedure.

Keywords

Main Subjects

References

[1] Makinouchi A(1996) Sheet metal forming simulation in industry. J Mater Process Tech 60: 19-26.
[2] Panthi SK, Ramakrishnan N, Pathak KK, Chouhan JS (2007) An analysis of springback in sheet metal bending using finite element method (FEM). J Mater Process Tech 186: 120-124.
[3] Dong HZ, Lin ZQ (2000) Investigation of sheet metal forming by numerical simulation and experiment. J Mater Process Tech 103: 404-410.
[4] Ohata T, Nakamura Y, Katayama T, Nakamachi E, Nakano K (1996) Development of optimum process design system by numerical simulation. J Mater Process Tech 60: 543-548.
[5] Guo YQ, Batoz JL, Naceur H, Bouabdallah S, Mercier F, Barlet O (2000) Recent developments on the analysis and optimum design of sheet metal forming parts using a simplified inverse approach. Comput Struct 78: 133-148.
[6] Naceur H, Guo YQ, Batoz JL, Knopf-Lenoir C (2001) Optimization of drawbead restraining forces and drawbead design in sheet metal forming process. Int J Mech Sci 43: 2407-2434.
[7] Kayabasi O, Ekici B (2007) Automated design methodology for automobile side panel die using an effective optimization approach. Mater Design 28: 2665-2672.
[8] Chen L, Yang JC, Zhang LW, Yuan SY (2007) Finite element simulation and model optimization of blankholder gap and shell element type in the stamping of a washing-trough. J Mater Process Tech 182: 637-643.
[9] Azaouzi M, Naceur H, Delameziere A, Batoz JL, Belouettar S (2008) An Heuristic optimization algorithm for the blank shape design of high precision metallic parts obtained by a particular stamping process. Finite Elem Anal Des 842-850.
[10] Khalili Kh, Kahhal P, Efthekhari Shahri E, Khalili MS (2011) Blank optimization in elliptical-shaped sheet metal forming using response surface model coupled by reduced basis technique and finite element analysis. Key Eng Mat 473: 683-690.
[11] Huang Y, Lo ZY, Du R (2006) Minimization of the thickness variation in multi-step sheet metal stamping. J Mater Process Tech 177: 84-86.
[12] Ohata T, Nakamura Y, Katayama T, Nakamachi E (2003) Development of optimum process design system for sheet fabrication using response surface method. J Mater Process Tech 143-144: 667-672.
[13] Hu W, Yao LG, Hua ZZ (2008) Optimization of sheet metal forming processes by adaptive response surface based on intelligent sampling method. J Mater Process Tech 197: 77-88.
[14] Jansson T, Nilsson L (2006) Optimizing sheet metal forming processes – using a design hierarchy and response surface methodology. J Mater Process Tech 178: 218-233.
[15] Jansson T, Andersson A, Nilsson L (2005) Optimization of draw-in for an automotive sheet metal part: an evaluation using surrogate models and response surfaces. J Mater Process Tech 159: 426-434.
[16] Guangyong S, Guangyao L, Zhihui G, Xiangyang C, Xujing Y, Qing L (2010) Multiobjective robust optimization method for drawbead design in sheet metal forming. Mater Design 31: 1917-1929.
[17] Konak A, Coit DW, Smith AE (2006) Multi-objective optimization using genetic algorithms: A tutorial. Reliab Eng Syst Safe 91(9): 992-1007.
[18] Farhang-Mehr A, Azarm S (2002) Entropy-based multi-objective genetic algorithm for design optimization. Struct Multidiscip O 24: 351-361.
[19] Hiroyasu T, Miki M, Kamiura J, Watanabe S, Hiroyasu H (2002) Multi-objective optimization of diesel engine emissions and fuel economy using genetic algorithms and phenomenological model. SAE paper no. 2002-01-2778.
[20] Kasprzak EM, Lewis KE (2001) Pareto analysis in multiobjective optimization using the collinearity theorem and scaling method. Struct Multidiscip O 22: 208-218.
[21] Liu W, Yang Y(2008) Multi-objective optimization of sheet metal forming process using Pareto-based genetic algorithm. J Mater Process Tech 208: 499-506.
[22] Kahhal P, Ahmadi SY, Deilami H (2013) Multi-objective optimization of sheet metal forming die using genetic algorithm coupled with RSM and FEA. J Fail Anal Prev 13(6): 771.
[23] Hosford WF, Caddel RM (2007) Metal Forming Mechanics and Metallurgy. Cambridge University Press, chapter 15, 241-244.
[24] صفری،  م (1388) بررسی تجربی و شبیه سازی اجزای محدود اثر نرخ کرنش بر نمودار حد شکل دهی ورق آلومینیومی 3105. پایان نامه مقطع کارشناسی ارشد، بابل، دانشگاه مازندران.
[25] ایری، د (1387) اصول پرسکاری و طراحی قالب پرس. ترجمه مسعود رخش خورشید، انتشارات جهان نو.
Journal of Solid and Fluid Mechanics
Volume 6, Issue 2
July and August 2016
Pages 167-179

Files

Share

How to cite

Statistics