scholarly journals Surrogate model–based inverse parameter estimation in deep drawing using automatic knowledge acquisition

2021 ◽  
Author(s):  
Matthias Ryser ◽  
Felix M. Neuhauser ◽  
Christoph Hein ◽  
Pavel Hora ◽  
Markus Bambach
Keyword(s):  
Knowledge Acquisition ◽  
Process Parameters ◽  
Deep Drawing ◽  
Blank Holder ◽  
Target Values ◽  
Simulation Based ◽  
Column Subset Selection ◽  
Automatic Knowledge Acquisition ◽  
Sensor Signals

AbstractIn this paper, we propose a new approach for the simulation-based support of tryout operations in deep drawing which can be schematically classified as automatic knowledge acquisition. The central idea is to identify information maximising sensor positions for draw-in as well as local blank holder force sensors by solving the column subset selection problem with respect to the sensor sensitivities. Inverse surrogate models are then trained using the selected sensor signals as predictors and the material and process parameters as targets. The final models are able to observe the drawing process by estimating current material and process parameters, which can then be compared to the target values to identify process corrections. The methodology is examined on an Audi A8L side panel frame using a set of 635 simulations, where 20 out of 21 material and process parameters can be estimated with an R2 value greater than 0.9. The result shows that the observational models are not only capable of estimating all but one process parameters with high accuracy, but also allow the determination of material parameters at the same time. Since no assumptions are made about the type of process, sensors, material or process parameters, the methodology proposed can also be applied to other manufacturing processes and use cases.

Optimization on Deep Drawing and Ironing Process of Compressed Natural Gas Containers

2013 ◽  
Vol 401-403 ◽  
pp. 867-870 ◽  
Author(s):  
Wu Jiao Xu ◽  
Chun Hai Zhai ◽  
Wu Hua Li
Keyword(s):  
Friction Coefficient ◽  
Natural Gas ◽  
Process Parameters ◽  
Deep Drawing ◽  
Experimental Production ◽  
Compressed Natural Gas ◽  
Blank Holder ◽  
Actual Production ◽  
Simulation Results

In this article, the influence of different process parameters on the bottom thickness of CNG container during the deep drawing and ironing process has been analyzed by simulation. The bottom die fillet R, the spacer height H between blank holder and bottom die and the friction coefficient μ between punch and billet were selected as parameters for optimization. The simulation results reveals that the appropriate bottom die fillet R and spacer height H is needed to reduce the thinning of product bottom. Meanwhile, the bigger the friction coefficient μ, the thicker the product bottom. The optimized results were utilized in the experimental production and the products in the three passes meet the designed requirements, which illustrates that the simulation results have great help for the actual production.

Influence of the Key Process Parameters in Hydrodynamic Deep Drawing Utilizing a Combined Floating and Static Die Cavity

2021 ◽  
Author(s):  
Huiting Wang ◽  
Jianfei Kong ◽  
Hongbo Pan ◽  
Jinxiu Fang ◽  
Xiaohui Shen
Keyword(s):  
Process Parameters ◽  
Deep Drawing ◽  
Initial Pressure ◽  
Loading Path ◽  
Maximum Pressure ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Hydraulic Loading ◽  
Second Stage ◽  
Hydrodynamic Deep Drawing

Abstract This study focus on the effects of the key process parameters during a modified hydrodynamic deep drawing utilizing a combined floating and static die cavity (HDDC). A two-stage hydraulic loading path is recommended in the novel process, and each stage of the hydraulic loading path is a linear loading path with an inflection point. The method to evaluate the wrinkle and forming dimension precision of the formed parts is introduced at first. Then the influence of the key parameters of the two-stage hydraulic loading path as well as the blank holder force on the dimension accuracy and surface quality of the formed parts was studied in detail. The results showed that the influence of the liquid pressure during the second stage is more significant than that in the first stage in hydrodynamic deep drawing utilizing a combined floating and static die cavity. The initial pressure of the second stage and the maximum pressure arriving moment during this stage have a significant impact on the dimensional accuracy of the formed parts, and the smaller initial pressure or the later the maximum pressure of the second stage arrives, the higher the accuracy of the formed part is. Similarly, the influence of the blank holder force in the second stage on the forming accuracy is more significant than that in the first stage.

Deep Drawing of Square-Shaped Sheet Metal Parts, Part 2: Experimental Study

1993 ◽  
Vol 115 (1) ◽  
pp. 110-117 ◽  
Author(s):  
S. A. Majlessi ◽  
D. Lee
Keyword(s):  
Process Parameters ◽  
Deep Drawing ◽  
Process Conditions ◽  
Drawing Process ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Punch Load ◽  
Blank Size

The deep drawing process of square and rectangular shells were investigated under different process conditions, and using two different drawing quality steels. The main objective was to identify the significance of some of the process parameters on the outcome of the drawing operation. The process parameters examined were shape and size of blank, the blank-holder force and frictional condition between blank and tooling. The results of this investigation were presented in terms of punch load, through thickness and in-plane strain distributions, formations of flange wrinkles and fracture, and the largest possible blank size that can be drawn successfully. Some of these experimental results were used to verify the validity of a simplified analytical model which was described in the first part of this paper.

Prediction of Wrinkling and Determination of Minimum Blankholding Pressure in Multistage Deep Drawing

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
Anupam Agrawal ◽  
N. Venkata Reddy ◽  
P. M. Dixit
Keyword(s):  
Upper Bound ◽  
Deep Drawing ◽  
Maximum Amplitude ◽  
Thickness Variation ◽  
Process Conditions ◽  
Blank Holder ◽  
Analysis Methodology ◽  
Wrinkling Analysis ◽  
Process Constraints

Wrinkling in the flange region has been observed during redrawing operation by a few researchers. In the present work an analysis methodology, based on a combination of upper bound and energy approaches, is proposed for the prediction of number of wrinkles and minimum blankholding pressure necessary to avoid wrinkling in redrawing operation. Thickness variation predicted by the upper bound formulation is used as input for the wrinkling analysis by assuming a suitable waveform based on geometrical and process conditions. The flange is constrained at both ends, i.e., by the blank holder profile radius and at the die entry point (where the sheet enters into the die cavity). The waveform for present analysis is assumed such that it has zero displacement at both ends (since it is constrained) and the maximum amplitude of the wave at some point in between those ends. The wrinkling predicted by the present methodology seems to be reasonably accurate considering the geometrical and process constraints of the redraw.

EFFECTS OF MATERIAL ANISOTROPY AND PROCESS PARAMETERS ON THE EARING DURING CYLINDRICAL DEEP DRAWING PROCESS

2008 ◽  
Vol 07 (01) ◽  
pp. 131-135
Author(s):  
TUNG-SHENG YANG ◽  
RUEY-FANG SHYU
Keyword(s):  
Strain Hardening ◽  
Process Parameters ◽  
Deep Drawing ◽  
Strain Hardening Exponent ◽  
Drawing Process ◽  
Material Anisotropy ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Deep Drawing Process ◽  
Anisotropic Property

Deep drawing process is very useful in industrial field because of its efficiency. The earing of deep drawing process is affected by many material and process parameters, such as the strain-hardening exponent, anisotropic property of blank, blank holder force, the profile radius of die, etc. In this paper, the material anisotropy and process parameters effect on the earing are investigated.

OPTIMIZATION OF INFLUENTIAL PROCESS PARAMETERS ON THE DEEP DRAWING OF ALUMINIUM 6061 SHEET USING TAGUCHI AND FINITE ELEMENT METHOD

2015 ◽  
Vol 39 (3) ◽  
pp. 605-614 ◽  
Author(s):  
Van Quang Nguyen ◽  
Balamurugan Ramamurthy ◽  
Jau-Wen Lin
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Coefficient Of Friction ◽  
Process Parameters ◽  
Deep Drawing ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Edge Radius ◽  
Plastic Deformation Behavior ◽  
Element Method

The plastic deformation behavior of axis symmetric aluminium 6061 cups was determined by analyzing the four important deep drawing process parameters, namely blank temperature, die edge radius, blank holder force and friction coefficient. Taguchi techniques along with finite element method (FEM) were used to determine the importance of process parameters. The Taguchi method was used to analyze the influence of each process parameter. From the deformation result and analysis of variance (ANOVA), it was determined that the temperature of the blank has a major influence on the deformation characteristic of aluminium 6061 sheets followed by die edge radius, coefficient of friction, and blank holder force. The optimum levels of the four factors in determining the deformed cup heights are found to be blank temperature of 450°C, die edge radius of 14 mm, coefficient of friction of 0.60 and blank holder force of 9 KN.

scholarly journals Numerical Simulation of Damage on Warm Deep Drawing of Al 6061-T6 Aluminium Alloy

2019 ◽  
Vol 9 (5) ◽  
pp. 4830-4834
Author(s):  
W. Rajhi
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Process Parameters ◽  
Deep Drawing ◽  
Damage Evolution ◽  
Model Parameters ◽  
Blank Holder ◽  
Al 6061 ◽  
Warm Deep Drawing ◽  
Jc Model

This work focuses on the numerical simulation of warm deep drawing operation of car sump oil made with Al 6061-T6 aluminum alloy for the purpose of process optimization. The thermo visco-plastic behavior with damage effect of the material is described by the Johnson-Cook (JC) model. The JC model parameters for the Al 6061-T6 Aluminum alloy were exploited. Numerical simulation of the deep drawing operation was performed with the use of the ABAQUS FE software thanks to the dynamic Explicit Temperature-Displacement algorithm. The design of the different tools is obtained on the basis of the geometry of the finished product. Designing of punch, die and blank holder is performed using CATIA 3D CAD software. The warm forming method involves the heating of the blank holder and the die to a certain temperature, whereas, the punch is kept at room temperature. In this study, predefined temperatures of the die and blank holder and punch speed will be investigated among other stamping parameters. The computed damage evolution curves for a given set of the process parameters are retrieved at the end of the simulation to determine suitable forming conditions. It can be noted that the slower the damage evolution achieved within the blank, the more appropriate the process parameters. Thus, by increasing strain rate, main cracks change location.

A Study on Warm Hydroforming of Al and Mg Sheet Materials: Mechanism and Proper Temperature Conditions

2008 ◽  
Vol 130 (4) ◽  
Author(s):  
Ho Choi ◽  
Muammer Koç ◽  
Jun Ni
Keyword(s):  
Process Parameters ◽  
Control Process ◽  
Hydraulic Pressure ◽  
Element Analysis ◽  
Lightweight Materials ◽  
Blank Holder ◽  
Warm Hydroforming ◽  
Temperature Levels ◽  
Fully Coupled

Hydroforming of lightweight materials at elevated temperature is a relatively new process with promises of increased formability at low internal pressure levels. In this study, the mechanism of warm hydroforming processes is presented in terms of its formability by comparison with warm forming, and cold hydroforming processes. Additionally, a strategy is proposed to control process parameters, such as temperature, hydraulic pressure, blank holder force, and forming speed. As a part of this strategy, the proper temperature condition is determined by adaptive-isothermal finite element analysis (FEA) and a design of experiment (DOE) approach. The adaptive-isothermal FEA determines the temperature levels of the blank material, which is selectively heated, by checking position of the blank material and adopting temperature level of the neighboring tooling. The proposed adaptive-isothermal FEA/DOE approach leads to the optimal temperature condition in a warm hydroforming system accurately and rapidly as opposed to costly and lengthy experimental trial and errors and/or fully coupled thermo-mechanical simulations. Other process parameters are also optimized in a continued study (Choi et al., 2007, “Determination of Optimal Loading Profiles in Warm Hydroforming of Lightweight Materials,” J. Mater. Process. Techn., 190(1–3), pp. 230–242.).

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