Sequential multi-objective optimization of thin-walled aluminum alloy tube bending under various uncertainties

Abstract Combining the design of experiments (DOE) and three-dimensional finite element (3D-FE) method, a sequential multi-objective optimization of larger diameter thin-walled (LDTW) Al-alloy tube bending under uncertainties was proposed and implemented based on the deterministic design results. Via the fractional factorial design, the significant noise factors are obtained, viz, variations of tube properties, fluctuations of tube geometries and friction. Using the virtual Taguchi's DOE of inner and outer arrays, considering three major defects, the robust optimization of LDTW Al-alloy tube bending is achieved and validated. For the bending tools, the robust design of mandrel diameter was conducted under the fluctuations of tube properties, friction and tube geometry. For the processing parameters, considering the variations of friction, material properties and manufacture deviation of mandrel, the robust design of mandrel extension length and boosting ratio is realized.

[1]  H. Yang,et al.  Anisotropic and asymmetrical yielding and its distorted evolution: Modeling and applications , 2016 .

[2]  Mei Zhan,et al.  Effects of Process Parameters on Numerical Control Bending Process for Large Diameter thin-walled Aluminum Alloy Tubes , 2009 .

[3]  Mei Zhan,et al.  Friction role in bending behaviors of thin-walled tube in rotary-draw-bending under small bending radii , 2010 .

[4]  Yang He,et al.  Role of mandrel in NC precision bending process of thin-walled tube , 2007 .

[5]  Jie Xu,et al.  Knowledge-based substep deterministic optimization of large diameter thin-walled Al-alloy tube bending , 2013 .

[6]  Tapan P. Bagchi,et al.  Multiobjective Robust Design by Genetic Algorithms , 2003 .

[7]  Mei Zhan,et al.  Design and optimisation of mandrel parameters for thin walled aluminium alloy tube NC bending , 2011 .

[8]  He Yang,et al.  Warm bending mechanism of extrados and intrados of large diameter thin-walled CP-Ti tubes , 2014 .

[9]  Lucian Lăzărescu.  Effect of internal fluid pressure on quality of aluminum alloy tube in rotary draw bending , 2013 .

[10]  He Yang,et al.  Advances and Trends on Tube Bending Forming Technologies , 2012 .

[11]  Liming Peng,et al.  Bending Mechanisms in AM30 Alloy Tube Using a Rotary Draw Bender , 2010 .

[12]  He Yang,et al.  Tribological behaviors between commercial pure titanium sheet and tools in warm forming , 2015 .

[13]  Qing Li,et al.  Multiobjective robust optimization method for drawbead design in sheet metal forming , 2010 .

[14]  Torgeir Welo,et al.  Multiple instability-constrained tube bending limits , 2014 .

[15]  Heng Li,et al.  Significance-based optimization of processing parameters for thin-walled aluminum alloy tube NC bending with small bending radius , 2012 .

[16]  Matteo Strano.  Automatic tooling design for rotary draw bending of tubes , 2005 .