A new progressive design methodology for complex sheet metal stamping operations: Coupling spatially differentiated restraining forces approach and multi-objective optimization

The growing interest in sheet metal stamping processes, particularly in the automotive industry has led to three main issues in this field:*request of very complex shapes; *growing interest in springback control; *solution of multi-objective problems. These issues make a sheet metal stamping processes design very difficult and proper design methodologies to reduce times and costs are highly required. In this paper, a computer aided approach aiming to satisfy the mentioned issues is proposed. In particular, a progressive design approach based on the integration between numerical simulations, Response Surface Methodology (RSM) and Pareto optimal solutions search techniques was applied in order to design a complex 3D automotive stamping operation. An explicit/forming-implicit/springback approach was utilized to develop the numerical simulations. The proposed design approach is able to verify the necessity of a spatially differentiated restraining forces approach and to design the best policy for them. Pareto optimal solutions search techniques were applied in two different phases: the former Pareto frontier was built using an uniform restraining forces policy while the latter, which is the final process design tool, was based on a differentiated restraining forces strategy. Two different restraining force policies were applied: the former focused on drawbeads utilization, the latter utilized a segmented blankholder. As the optimization objective functions are concerned, indicators related both to thinning distribution and to springback amount were taken into account. The obtained Pareto curves can be used in order to discriminate which conditions have to be expected once a desired value of one of the objective functions is fixed. A new and flexible design methodology is proposed, able to:*deal with complex sheet metal stamping processes; *investigate many possible technological scenarios; *carry out a set of reliable solutions able to satisfy different design requirements.

[1]  Mehmet Firat,et al.  Prediction of springback in wipe-bending process of sheet metal using neural network , 2009 .

[2]  R. H. Wagoner,et al.  Simulation of springback: Through-thickness integration , 2007 .

[3]  R. H. Wagoner,et al.  Simulation of springback , 2002 .

[4]  Douglas C. Montgomery,et al.  Response Surface Methodology: Process and Product Optimization Using Designed Experiments , 1995 .

[5]  G. P. Liu,et al.  A novel multi-objective optimization method based on an approximation model management technique , 2008 .

[6]  Michael R. Lovell,et al.  Investigation of springback in high strength anisotropic steels , 2005 .

[7]  Giuseppe Ingarao,et al.  Analysis of stamping performances of dual phase steels: a multi-objective approach to reduce springback and thinning failure , 2009 .

[8]  Giuseppe Ingarao,et al.  Internal pressure and counterpunch action design in Y-shaped tube hydroforming processes: A multi-objective optimisation approach , 2009 .

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

[10]  Lin Wang,et al.  Controlled strain path forming process with space variant blank holder force using RSM method , 2005 .

[11]  R. H. Wagoner,et al.  Role of plastic anisotropy and its evolution on springback , 2002 .

[12]  Luc Papeleux,et al.  Finite element simulation of springback in sheet metal forming , 2002 .

[13]  D. Wei,et al.  Optimization and tolerance prediction of sheet metal forming process using response surface model , 2008 .

[14]  J. Dennis,et al.  A closer look at drawbacks of minimizing weighted sums of objectives for Pareto set generation in multicriteria optimization problems , 1997 .

[15]  Wang Hu,et al.  Optimization of drawbead design in sheet metal forming based on intelligent sampling by using response surface methodology , 2008 .

[16]  R. H. Wagoner,et al.  DIE DESIGN METHOD FOR SHEET SPRINGBACK , 2004 .

[17]  W. L. Xu,et al.  Sensitive factors in springback simulation for sheet metal forming , 2004 .

[18]  Ivo F. Sbalzariniy,et al.  Multiobjective optimization using evolutionary algorithms , 2000 .

[19]  Y. Guo,et al.  Response surface methodology for design of sheet forming parameters to control springback effects , 2006 .

[20]  ChangHwan Kim,et al.  System identification of simplified crash models using multi-objective optimization , 2006 .

[21]  A. Messac,et al.  Generating Well-Distributed Sets of Pareto Points for Engineering Design Using Physical Programming , 2002 .

[22]  P. Villon,et al.  Moving least squares response surface approximation: Formulation and metal forming applications , 2005 .

[23]  Yang Yuying,et al.  Multi-objective optimization of sheet metal forming process using Pareto-based genetic algorithm , 2008 .

[24]  Wang Hu,et al.  Optimization of sheet metal forming processes by the use of space mapping based metamodeling method , 2008 .

[25]  Hang Shawn Cheng,et al.  An accelerated springback compensation method , 2007 .

[26]  Yang Yuying,et al.  Springback control of sheet metal forming based on the response-surface method and multi-objective genetic algorithm , 2009 .

[27]  Kalyanmoy Deb,et al.  Multi-objective optimization using evolutionary algorithms , 2001, Wiley-Interscience series in systems and optimization.

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

[29]  Tomas Jansson,et al.  Optimization of Draw-In for an Automotive Sheet Metal Part An evaluation using surrogate models and response surfaces , 2005 .

[30]  Rajiv Shivpuri,et al.  Robust design of spatially distributed friction for reduced wrinkling and thinning failure in sheet drawing , 2009 .

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

[32]  Akitake Makinouchi,et al.  Simulation of springback and wrinkling in stamping of a dual phase steel rail-shaped part , 2006 .

[33]  Wolfgang Bleck,et al.  A Numerical and Experimental Investigation into Hot Stamping of Boron Alloyed Heat Treated Steels , 2008 .

[34]  Wei Liu,et al.  Multi-objective optimization of an auto panel drawing die face design by mesh morphing , 2007, Comput. Aided Des..