Design optimization of variable blank holder force trajectory and slide velocity in sheet metal forming

In sheet forming, the blank holder force (BHF) has a direct influence on product quality. A high BHF leads to tearing, whereas a low one results in wrinkling. For successful sheet forming, the BHF should be adjusted. Recently, the variable BHF (VBHF) that the BHF varies through stroke is recognized as one of the advanced sheet forming technologies. On the other hand, slide velocity (SV) that controls the die velocity is rarely discussed in the literature, and the SV should also be taken into account for the successful sheet forming. A high SV can achieve the high productivity, but wrinkling occurs. The VBHF trajectory and SV are unknown in advance, and the trial and error method is widely used. In this paper, design optimization approach using computational intelligence is adopted to determine them for achieving the high productivity. The processing time is taken as the objective function to be minimized for the high productivity. Numerical simulation in sheet forming is so intensive that a sequential approximate optimization using radial basis function network is adopted to determine the optimal solution. Based on the numerical result, the experiment using AC servo press (H1F200-2, Komatsu Industries Corp.) is carried out. Through the numerical and experimental result, the validity of proposed approach is examined.

[1]  Li Jian,et al.  Drawing motion profile planning and optimizing for heavy servo press , 2013 .

[2]  Frédéric Barlat,et al.  Advances in Sheet Forming—Materials Modeling, Numerical Simulation, and Press Technologies , 2011 .

[3]  R. E. Dick,et al.  Plane stress yield function for aluminum alloy sheets—part II: FE formulation and its implementation , 2004 .

[4]  Kozo Osakada,et al.  Controlled FEM Simulation for Determining History of Blank Holding Force in Deep Drawing , 1995 .

[5]  Wenfeng Zhang,et al.  Probabilistic design of aluminum sheet drawing for reduced risk of wrinkling and fracture , 2005, Reliab. Eng. Syst. Saf..

[6]  Satoshi Kitayama,et al.  Multi-objective optimization of blank shape for deep drawing with variable blank holder force via sequential approximate optimization , 2015 .

[8]  Zhen Zhao,et al.  Compound deep drawing and extrusion process for the manufacture of geared drum , 2016 .

[9]  J. Batoz,et al.  Response surface methodology for the rapid design of aluminum sheet metal forming parameters , 2008 .

[10]  Hiroki Koyama,et al.  Numerical and experimental case study on simultaneous optimization of blank shape and variable blank holder force trajectory in deep drawing , 2017 .

[11]  K. Yamazaki,et al.  Sequential Approximate Optimization using Radial Basis Function network for engineering optimization , 2011 .

[12]  Taylan Altan,et al.  Adaptive FEM simulation for prediction of variable blank holder force in conical cup drawing , 2004 .

[13]  Sachin S. Sapatnekar,et al.  Design by optimization , 2009 .

[14]  Wang Hu,et al.  Optimization of sheet metal forming processes by adaptive response surface based on intelligent sampling method , 2008 .

[15]  Shouichirou Yoshihara,et al.  Development of a combination punch speed and blank-holder fuzzy control system for the deep-drawing process , 2002 .

[16]  F. Yoshida,et al.  Experimental Observation of Elasto-Plasticity Behavior of Type 5000 and 6000 Aluminum Alloy Sheets , 2011 .

[17]  Koetsu Yamazaki,et al.  Optimization of variable blank holder force trajectory by sequential approximate optimization with RBF network , 2012 .

[18]  Taylan Altan,et al.  Mechanical servo press technology for metal forming , 2011 .

[19]  Masao Arakawa,et al.  Sequential approximate multi-objective optimization using radial basis function network , 2013 .

[20]  Abbas Hosseini,et al.  A hybrid NN-FE approach to adjust blank holder gap over punch stroke in deep drawing process , 2014 .

[21]  Chen Guanlong,et al.  A new strategy to optimize variable blank holder force towards improving the forming limits of aluminum sheet metal forming , 2007 .

[22]  Koetsu Yamazaki,et al.  814 The Square Cup Deep Drawing by Variable Blank Holder Force , 2010 .

[23]  Koetsu Yamazaki,et al.  Design optimization of initial blank shape and segmented variable blank holder force trajectories in deep drawing , 2017 .