Kriging metamodel global optimization of clinching joining processes accounting for ductile damage

Clinching is a very cheap and efficient cold forming process that enables to join two sheets without any additional part such as a rivet or a bolt. This paper deals with the optimization of the final mechanical strength of a joined component using a global optimization technique based on Kriging meta-model. The optimization process includes both the joining stage and the mechanical strength simulations. It is shown that accounting for plastic strain, residual stresses and damage occurring during clinching is essential if one wants to study the final mechanical strength of the clinched component. The global optimization leads to a 13.5% increase of the mechanical strength for tensile loading and to 46.5% increase for shear loading. The global optimization procedure also enables to study the influence of input geometrical variability on the final mechanical strength, which is essential from an industrial point of view.

[1]  Dimitri Debruyne,et al.  Reproducing the experimental pull-out and shear strength of clinched sheet metal connections using FEA , 2011 .

[2]  Elisabetta Ceretti,et al.  Editorial: The 13th International Conference on Material Forming , 2010 .

[3]  Pierre-Olivier Bouchard,et al.  Ductile damage parameters identification for cold metal forming applications , 2011 .

[4]  J. Lemaître.  A CONTINUOUS DAMAGE MECHANICS MODEL FOR DUCTILE FRACTURE , 1985 .

[5]  Michael T. M. Emmerich,et al.  Single- and multiobjective evolutionary optimization assisted by Gaussian random field metamodels , 2006, IEEE Transactions on Evolutionary Computation.

[6]  V. Hamel,et al.  Finite element modeling of clinch forming with automatic remeshing , 2000 .

[7]  Hans-Georg Beyer,et al.  A Comparison of Evolution Strategies with Other Direct Search Methods in the Presence of Noise , 2003, Comput. Optim. Appl..

[8]  Jean-Louis Batoz,et al.  Shape optimization of clinching tools using the response surface methodology with Moving Least-Square approximation , 2009 .

[9]  Sébastien Roth,et al.  The optimal design of sheet metal forming processes: application to the clinching of thin sheets , 2012, Int. J. Comput. Appl. Technol..

[10]  Thomas J. Santner,et al.  The Design and Analysis of Computer Experiments , 2003, Springer Series in Statistics.

[11]  Donald R. Jones,et al.  Efficient Global Optimization of Expensive Black-Box Functions , 1998, J. Glob. Optim..

[12]  Jean-Jacques Droesbeke,et al.  Analyse statistique des données spatiales , 2006 .

[13]  Barry L. Nelson,et al.  Stochastic kriging for simulation metamodeling , 2008, 2008 Winter Simulation Conference.

[14]  Pierre-Olivier Bouchard,et al.  Numerical investigation of ductile damage parameters identification: benefit of local measurements , 2011 .

[15]  Jean-Loup Chenot,et al.  Numerical and experimental studies of the riveting process , 2011 .

[16]  Robert H. Wagoner,et al.  Metal Forming Analysis , 2001 .

[17]  Dimitri Debruyne,et al.  Numerical and experimental study of the multi-axial quasi-static strength of clinched connections , 2013 .

[18]  Dimitri Debruyne,et al.  Analytical method to predict the pull-out strength of clinched connections , 2012 .

[19]  M. Oudjene,et al.  On the parametrical study of clinch joining of metallic sheets using the Taguchi method , 2008 .

[20]  C. Gruau,et al.  3D tetrahedral, unstructured and anisotropic mesh generation with adaptation to natural and multidomain metric , 2005 .

[21]  Pierre-Olivier Bouchard,et al.  An enhanced Lemaitre model formulation for materials processing damage computation , 2011 .

[22]  Raju Sethuraman,et al.  A continuum damage mechanics model for ductile fracture , 2000 .

[23]  Pierre-Olivier Bouchard,et al.  Numerical modeling of self-pierce riveting—From riveting process modeling down to structural analysis , 2008 .

[24]  D. Ginsbourger,et al.  Kriging is well-suited to parallelize optimization , 2010 .

[25]  Xiaocong He,et al.  Recent development in finite element analysis of clinched joints , 2010 .

[26]  Byung-Min Kim,et al.  Design of mechanical clinching tools for joining of aluminium alloy sheets , 2010 .