Design and Optimization of Stamping Process to Improve Manufacturing Feasibility

2000 ◽  
Author(s):  
H. Naceur ◽  
Y. Q. Guo ◽  
J. L. Batoz
Keyword(s):  
Numerical Procedure ◽  
Optimization Procedure ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Programming Technique ◽  
Design And Optimization ◽  
Stamping Process ◽  
Design Variables ◽  
Risk Of Rupture ◽  
Analytical Sensitivities

Abstract In this paper, we present a numerical procedure combining a finite element inverse approach (I.A.) [10, 14–18] for the simplified analysis of the stamping process with a mathematical programming technique (BFGS method) to optimize some process parameters. Our objective is to optimize the quality of the final workpiece, by minimizing the risk of rupture and wrinkles. The design variables of the present problem are the drawbead restraining forces in relation with the Forming Limit Diagram (FLD). The optimization procedure associated to the analytical sensitivities analysis technique based on the adjoint method is applied for the square cup of Numisheet’93 and the Twingo dashpot cup proposed by RENAULT [32]. The satisfactory results demonstrate the usefulness of this automatic optimization procedure in the preliminary design of deep-drawing process.

Forming Defects Analysis of Auto-Panel Stamped Part with Experimental Strain Approach

2004 ◽  
Vol 471-472 ◽  
pp. 503-507
Author(s):  
H.Y. Xiang ◽  
Yue Xian Zhong
Keyword(s):  
Experimental Method ◽  
Strain Distribution ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Practical Case ◽  
Stamping Process ◽  
Automobile Panel ◽  
Defects Analysis ◽  
Forming Defects ◽  
Stamped Part

This document explains and demonstrates an experimental method to determine principal plastic strains in industrially stamped sheet panels. The principal strains distribution after a given stamping process can be obtained using computer aided grid experimental method. In contrast with FLD (Forming Limit Diagram) obtained by the material testing, the measured results of strain distribution can be used to determine the sheet metal’s formability allowing to determine at which point the sheet metal cracks or uneven stretch occurs and other forming defects. The main principle and related theory of this approach are discussed. One automobile panel stamped part as a practical case was studied, the strain distribution of the part after a given stamping process was measured and calculated, a demonstration of how to deal with the results in comparison with FLD to determine and solve forming problems is analyzed.

OPTIMUM DESIGN OF REINFORCED CONCRETE FOUNDATIONS

2020 ◽  
Vol 14 ◽  
Author(s):  
Osama Bedair
Keyword(s):  
Reinforced Concrete ◽  
Cost Function ◽  
Numerical Procedure ◽  
Optimization Procedure ◽  
Analytical Models ◽  
Design Parameters ◽  
Foundation Design ◽  
Programming Technique ◽  
Concrete Foundation ◽  
The Cost

Background: Optimization of reinforced concrete foundation is a challenging problem in practice due to interaction between the design variables and constraints. Classical design methods may overestimate the size of the foundation, thus leading to excessive cost. By using current advances in computer technologies and numerical optimization procedures, it is possible to find the optimum combinations of foundations design parameters that minimize the cost. Objectives: The paper presents a numerical strategy to optimize the design of reinforced concrete foundation. Method: The cost function is first derived in terms of the foundation design parameters. Mathematical programming technique is utilized to minimize the cost function. Design constraints are used against soil bearing capacity, concrete shear strength, flexural strength and column bearing. Simplified analytical models are developed to idealize the soil stress distribution. The numerical procedure is then automated in a computer Program “OSFD” to perform sensitivity analysis and provide guidelines that can be utilized in practice. Results: Design examples are provided to illustrate efficiency of the optimization procedure. Results are compared with exiting conventional design procedures, commercial softwares and design handbooks available in practice. Conclusions: The described procedure is very cost effective that can be effectively utilized by practicing Engineers in the industry to optimize the design of reinforced concrete foundation.

scholarly journals Design, Experimental and Numerical Characterization of 3D-Printed Porous Absorbers

Materials ◽  
2019 ◽  
Vol 12 (20) ◽  
pp. 3397 ◽  
Author(s):  
Tobias P. Ring ◽  
Sabine C. Langer
Keyword(s):  
Porous Materials ◽  
Optimization Procedure ◽  
Geometric Design ◽  
Room Acoustics ◽  
Noise Mitigation ◽  
Design And Optimization ◽  
Numerical Characterization ◽  
Design Variables ◽  
3D Printed ◽  
Set Up

The application of porous materials is a common measure for noise mitigation and in room acoustics. The prediction of the acoustic behavior applies material models, among which most are based on the Biot-parameters. Thereby, it is expected that, if more Biot-parameters are used, a better prediction can be obtained. Nevertheless, an estimation of the Biot-parameters from the geometric design of the material is possible for simple structures only. For common porous materials, the microstructure is typically unknown and characterized by homogenized quantities. This contribution introduces a methodology that enables the design and optimization of porous materials based on the Biot-parameters and connects these to microscopic geometric quantities. Therefore, artificial porous materials were manufactured using 3D-printing technology with a prescribed geometric design and the influence of different design variables was investigated. The Biot-parameters were identified with an inverse procedure and it can be shown that different Biot-parameters can be influenced by adjusting the geometric design variables. Based on these findings, a one-parameter optimization procedure of the material is set up to maximize the absorption characteristics in the frequency range of interest.

A Design Method for Minimizing the Sound Power Radiated from Plates by Adding Optimally Sized, Discrete Masses

1995 ◽  
Vol 117 (B) ◽  
pp. 243-251 ◽  
Author(s):  
R. L. St. Pierre ◽  
G. H. Koopmann
Keyword(s):  
Design Method ◽  
Optimization Procedure ◽  
Single Frequency ◽  
Mode Shapes ◽  
Test Case ◽  
Sound Power ◽  
Design Variables ◽  
Resonant Modes ◽  
Minimization Procedure ◽  
Analytical Sensitivities

In this paper, a novel method for minimizing the sound power radiated from a structure is presented. The method involves placing strategically sized masses at specific locations on the structure’s surface. The minimization procedure modifies the shapes of the resonant modes of the structure in the frequency range of interest such that they are forced to radiate sound inefficiently. Because of this, they are referred to as “weak radiator” mode shapes. The method uses an optimization procedure that directly minimizes the radiated sound power from the surface of a plate in an infinite baffle. The procedure can be carried out for a single frequency or over a range of frequencies. Analytical sensitivities of sound power with respect to the design variables are developed and used in the optimization algorithm. Results on various test cases show sound power reductions of 10 dB or more even when several resonances are included in the frequency band. An acoustic intensity probe is used to experimentally verify the results for one test case. The experiment confirms the sound power reductions predicted by the optimization program.

ADAPTIVE BONE REMODELING CRITERIA APPLIED TO DESIGN OPTIMIZATION OF FEMORAL COMPONENT OF HIP PROSTHESES

2005 ◽  
Vol 05 (01) ◽  
pp. 191-202 ◽  
Author(s):  
HAMID KATOOZIAN ◽  
ZOHREH BARANI ◽  
DWIGHT T. DAVY
Keyword(s):  
Femoral Component ◽  
Numerical Procedure ◽  
Optimization Procedure ◽  
3D Design ◽  
Element Analysis ◽  
Physiological Factors ◽  
Hip Prostheses ◽  
Total Hip ◽  
Design Variables ◽  
Hip Replacements

Considering effects of physiological factors in failure of total hip arthroplasty, a numerical procedure was implemented for the three-dimesional (3D) shape optimization of femoral component of total hip replacements on the basis of remodeling objective functions. Design variables are the shape parameters, which define the femoral component geometry. The 3D design model was incorporated with 3D finite element analysis and a numerical optimization procedure. The main optimization goal was to reduce the potential for change of the bone morphology and to keep it close to the normal condition of an intact femur, by changing the geometry of the implant. Both local and global remodeling goals were examined. The results suggest a much more slender implant than is normally used would be required to minimize the remodeling potential. The results also demonstrated that the outcomes are indeed sensitive to whether the remodeling goal is treated as local or global.

A Design Method for Minimizing the Sound Power Radiated from Plates by Adding Optimally Sized, Discrete Masses

1995 ◽  
Vol 117 (B) ◽  
pp. 243-251 ◽  
Author(s):  
R. L. St. Pierre ◽  
G. H. Koopmann
Keyword(s):  
Design Method ◽  
Optimization Procedure ◽  
Single Frequency ◽  
Mode Shapes ◽  
Test Case ◽  
Sound Power ◽  
Design Variables ◽  
Resonant Modes ◽  
Minimization Procedure ◽  
Analytical Sensitivities

In this paper, a novel method for minimizing the sound power radiated from a structure is presented. The method involves placing strategically sized masses at specific locations on the structure’s surface. The minimization procedure modifies the shapes of the resonant modes of the structure in the frequency range of interest such that they are forced to radiate sound inefficiently. Because of this, they are referred to as “weak radiator” mode shapes. The method uses an optimization procedure that directly minimizes the radiated sound power from the surface of a plate in an infinite baffle. The procedure can be carried out for a single frequency or over a range of frequencies. Analytical sensitivities of sound power with respect to the design variables are developed and used in the optimization algorithm. Results on various test cases show sound power reductions of 10 dB or more even when several resonances are included in the frequency band. An acoustic intensity probe is used to experimentally verify the results for one test case. The experiment confirms the sound power reductions predicted by the optimization program.

Research on Structural Design and Optimization of Turbine Blade Shroud

2012 ◽  
Author(s):  
Jiang Fan ◽  
Le Han ◽  
Rongqiao Wang ◽  
Xiuli Shen ◽  
Weiwei Zeng ◽  
...  
Keyword(s):  
Turbine Blade ◽  
Structural Design ◽  
Twist Angle ◽  
Optimization Procedure ◽  
Optimization Approach ◽  
Optimized Design ◽  
Design And Optimization ◽  
Structural Intensity ◽  
Design Variables ◽  
Angle Parameter

An automatic optimization approach for the structural design of turbine blade shroud is presented and applied to the optimal design of a zigzag shroud in this paper. It integrates commercial CAD and CAE softwares into optimization procedure iSIGHT. According to the normal rules of the shroud design and experience, this paper advises a zigzag shroud which is fit for a kind of turbine blade. The parametric model of the shroud is established and the pre-twist angle parameter is taken into consideration. The structural intensity performance of the shroud, which is used to compute the optimal objective and constraints during optimization, is determined by conducting coupled thermal-structural analysis of shrouded turbine blade using the commercial Finite Element code ANSYS. Two application examples of the optimization approach are presented, with optimal objective functions of shrouded blade mass and maximum shroud contact pressure respectively. The latter includes the pre-twist angle as one of design variables. Mechanical and geometry constraints are applied on the design to ensure that the optimized design meets requirements for feasibility of engineering criteria. Simulation results from shroud optimizations by means of the optimization approach prove that the performance of the shroud can be improved significantly through structure optimization. The optimization approach provides an effective method to design and optimize the similar complicated models.

Optimization of Tube Hydroforming Process Using Probabilistic Constraints on Failure Modes

2011 ◽  
Vol 62 ◽  
pp. 21-35 ◽  
Author(s):  
Anis Ben Abdessalem ◽  
A. El Hami
Keyword(s):  
Failure Modes ◽  
High Reliability ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Forming Limit Diagram ◽  
Plastic Instability ◽  
Probabilistic Constraints ◽  
Forming Limit ◽  
Reliability Based Design ◽  
Hydroforming Process

In metal forming processes, different parameters (Material constants, geometric dimensions, loads …) exhibits unavoidable scatter that lead the process unreliable and unstable. In this paper, we interest particularly in tube hydroforming process (THP). This process consists to apply an inner pressure combined to an axial displacement to manufacture the part. During the manufacturing phase, inappropriate choice of the loading paths can lead to failure. Deterministic approaches are unable to optimize the process with taking into account to the uncertainty. In this work, we introduce the Reliability-Based Design Optimization (RBDO) to optimize the process under probabilistic considerations to ensure a high reliability level and stability during the manufacturing phase and avoid the occurrence of such plastic instability. Taking account of the uncertainty offer to the process a high stability associated with a low probability of failure. The definition of the objective function and the probabilistic constraints takes advantages from the Forming Limit Diagram (FLD) and the Forming Limit Stress Diagram (FLSD) used as a failure criterion to detect the occurrence of wrinkling, severe thinning, and necking. A THP is then introduced as an example to illustrate the proposed approach. The results show the robustness and efficiency of RBDO to improve thickness distribution and minimize the risk of potential failure modes.

Formability Analysis of AA6061 Sheet in T6 Condition

2015 ◽  
Vol 766-767 ◽  
pp. 416-421
Author(s):  
S. Vijayananth ◽  
V. Jayaseelan ◽  
G. Shivasubbramanian
Keyword(s):  
Experimental Method ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Ansys Software ◽  
Limit Curve ◽  
High Corrosion Resistance ◽  
Forming Limit Curve ◽  
Drawing Test ◽  
Deep Drawing Test ◽  
Alloy 6061

Formability of a material is defined as its ability to deform into desired shape without being fracture. There will always be a need for formability tests, a larger number of tests have been used in an effort to measure the formability of sheet materials. Aluminium Alloy 6061 is a magnesium and silicon alloy of aluminium. It is also called as marine material as it has high corrosion resistance to seawater. In this paper Formability test of AA6061 sheet is done by Forming Limit Diagram (FLD) Analysis. FLD or Forming Limit Curve (FLC) for the forming processes of AA6061 sheets is obtained by Experimental method and FEM. Experimental method involves Deep drawing test of the sheet and ANSYS software is used for FEM.

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