Abstract
This article presents the optimization of process parameters in reducing the risk of failure due to wrinkling and fracture in deep drawing of a rectangular cup. Blank holder force, friction coefficient, punch radius and initial blank shape were chosen as design parameters. Wrinkling and fracture criteria were used as objective functions. Two-stage optimization approach was used. In the first stage optimization, optimum blank shape was determined using the Taguchi optimization method. In the second stage optimization, optimum parameter values were determined for the selected blank shape by the first stage optimization using genetic algorithm. In the second stage of optimization, response surface models based on 3-level full factorial design of experiments were constructed. Finite element simulation results were used for creating response surface models. Parameters obtained from optimization study were confirmed by conducting deep drawing simulations using commercial code DYNAFORM 5.9.2. Optimum results showed that proposed optimization methodology can solve wrinkling and fracture problems in the sheet metal forming process.
Abstract
In diesem Beitrag wird die Optimierung von Prozessparametern vorgestellt, um das Risiko eines Versagens infolge Knitterns und Bruchs beim Tiefziehen einer rechtwinkligen Form zu reduzieren. Die Haltekraft des Rohlings, der Reibkoeffizient, der Stempelradius und die Ausgangsform des Rohlings wurden als Designparameter ausgewählt. Die Knitter- und die Bruchkriterien wurden als Zielfunktionen verwendet. Es wurde ein zweistufiger Optimierungsprozess angewandt. In der ersten Stufe der Optimierung wurde die optimale Form des Rohlings mittels des Taguchi-Optimierungsverfahrens bestimmt. In der zweiten Optimierungsstufe wurden Antwort-Oberflächenmodelle basierend auf einem vollen faktoriellen Design der Experimente für drei Ebenen konstruiert. Es wurden Ergebnisse von Finite Elemente Simulationen genutzt, um die Antwort-Oberflächenmodelle zu kreieren. Die Parameter, die sich aus der Optimierungsstudie ergaben, wurden bestätigt, indem Tiefziehsimulationen mittels des kommerziellen Codes DYNAFORM 5.9.2 ausgeführt wurden. Die optimalen Ergebnisse zeigen, dass die vorgeschlagene Optimierungsmethode die Schwierigkeiten infolge Knitterns oder Bruchs in der Metallblechumformung lösen kann.
About the authors
MSc Bora Sener, born in 1984, studied Mechanical Engineering and finished his BSc in the Materials Science and Manufacturing Technologies Division of the Department of Mechanical Engineering at Yildiz Technical University, Istanbul, Turkey, where he has been working as a researcher since 2011. Sheet metal forming, mechanical behavior of materials and finite element analysis are his primary topics of interest.
Associate Professor Dr. Hasan Kurtaran, born in 1970, studied Aerospace Engineering. He completed his MSc and his PhD at George Washington University, USA, in 1995 and 2001, respectively. He has been Associate Professor at Gebze Technical University, Turkey, since 2010. The primary topics of his scientific work are finite element analysis, design optimization, metal forming, computer aided design, machine design and solid mechanics and dynamics.
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