scholarly journals An Optimization of the New Die Design of Sheet Hydroforming by Taguchi Method

2011 ◽  
Vol 337 ◽  
pp. 294-299
Author(s):  
Morteza Hosseinzadeh ◽  
S. Ali Zamani ◽  
Ali Taheri
Keyword(s):  
Taguchi Method ◽  
Optimal Combination ◽  
Die Design ◽  
Effective Parameters ◽  
Taguchi Optimization ◽  
Sheet Hydroforming ◽  
Confirmation Test ◽  
Die Set ◽  
Hydroforming Process ◽  
Optimization Methodology

During the last few years, several sheet hydroforming processes have been introduced. Despite the advantages of these methods, they have some limitations. Of the processes, the two main ones are the standard hydroforming and hydromechanical deep drawing. A new sheet hydroforming die set was proposed that has the advantages of both processes and eliminates their limitations. In this method, a polyurethane plate was used as a part of the die-set to control the blank holder force. This paper outlines the Taguchi optimization methodology, which is applied to optimize the effective parameters in forming cylindrical cups by the new die set of sheet hydroforming process. The process parameters evaluated in this research are polyurethane hardness, polyurethane thickness, forming pressure path and polyurethane hole diameter. The design of experiments based upon L9 orthogonal arrays by Taguchi was used and analysis of variance (ANOVA) was employed to analyze the effect of these parameters on the forming pressure. The analysis of the results showed that the optimal combination for low forming pressure is harder polyurethane, bigger diameter of polyurethane hole and thinner polyurethane. Finally, the confirmation test was derived based on the optimal combination of parameters and it was shown that the Taguchi method is suitable to examine the optimization process.

The Effect of Polyurethane Hardness on the New Die-Set of Sheet Hydroforming Process Parameters

2012 ◽  
Vol 152-154 ◽  
pp. 1623-1627
Author(s):  
Morteza Hosseinzadeh
Keyword(s):  
Process Parameters ◽  
Thickness Distribution ◽  
Effective Parameters ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Sheet Hydroforming ◽  
Die Set ◽  
Hydroforming Process

In recent years, several sheet hydroforming methods have been introduced by researchers. Despite the advantages of these methods, they have some limitations. The author [1] already proposed a novel sheet hydroforming method that is a combination of the standard and hydromechanical sheet hydroforming processes. The proposed method has the advantages of both processes and eliminates their limitations. In this method, a polyurethane diaphragm was used as a part of die-set to control the blank holder force. In this paper, the effect of polyurethane hardness on the effective parameters of the combined sheet hydroforming die-set such as forming pressure, thickness distribution of formed cup and maximum thinning zone of formed cup was investigated experimentally. It was shown that a softer polyurethane needs to a higher oil pressure to prevent wrinkling in the flange of the part. And tearing occurs at higher level of forming pressure. Also it was shown that by softer polyurethane, better thickness distribution was obtained.

scholarly journals Design Optimization of the Aeronautical Sheet Hydroforming Process Using the Taguchi Method

2019 ◽  
Vol 9 (9) ◽  
pp. 1932 ◽  
Author(s):  
Aurelio Muñoz-Rubio ◽  
David Bienvenido-Huertas ◽  
Francisco Javier Bermúdez-Rodríguez ◽  
Manuel Tornell-Barbosa
Keyword(s):  
Friction Coefficient ◽  
Taguchi Method ◽  
Aluminium Alloy ◽  
Elastic Recovery ◽  
Sheet Material ◽  
Alloy Sheet ◽  
Control Factors ◽  
Hydroforming Process ◽  
Optimization Methodology ◽  
Noise Factors

The aluminium alloy sheet forming processes forging in rubber pad and diaphragm presses (also known as hydroforming processes) are simple and economical processes adapted to aeronautical production. Typical defects of these processes are elastic recovery, necking, and wrinkling, and they present difficulties in control mainly due to property variations of the sheet material that take place during the process. In order to make these processes robust and unresponsive to material variations, a multiobjective optimization methodology based on the Taguchi method is proposed in the present study. The design of experiments and process simulation are combined in the methodology, using the nonlinear finite element method. The properties of sheet material are considered noise factors of the hydroforming process, the objective being to find a combination of the control factors that causes minimal defects to noise factors. The methodology was applied to an AA2024-T3 aluminium alloy sheet of 1 mm thickness stamping process in a diaphragm press. The results allowed us to establish the optimal pressure values, friction coefficient between sheet and block, and friction coefficient between sheet and rubber to reduce the elastic recovery variations and the minimal thickness before noise facts.

scholarly journals Optimization of a 3D-Printed Permanent Magnet Coupling Using Genetic Algorithm and Taguchi Method

Electronics ◽  
2021 ◽  
Vol 10 (4) ◽  
pp. 494
Author(s):  
Ekaterina Andriushchenko ◽  
Ants Kallaste ◽  
Anouar Belahcen ◽  
Toomas Vaimann ◽  
Anton Rassõlkin ◽  
...  
Keyword(s):  
Genetic Algorithm ◽  
Taguchi Method ◽  
Permanent Magnet ◽  
Optimization Problems ◽  
Optimization Method ◽  
Taguchi Optimization ◽  
Torque Density ◽  
Electromagnetic Devices ◽  
3D Printed ◽  
Manufacturing Techniques

In recent decades, the genetic algorithm (GA) has been extensively used in the design optimization of electromagnetic devices. Despite the great merits possessed by the GA, its processing procedure is highly time-consuming. On the contrary, the widely applied Taguchi optimization method is faster with comparable effectiveness in certain optimization problems. This study explores the abilities of both methods within the optimization of a permanent magnet coupling, where the optimization objectives are the minimization of coupling volume and maximization of transmitted torque. The optimal geometry of the coupling and the obtained characteristics achieved by both methods are nearly identical. The magnetic torque density is enhanced by more than 20%, while the volume is reduced by 17%. Yet, the Taguchi method is found to be more time-efficient and effective within the considered optimization problem. Thanks to the additive manufacturing techniques, the initial design and the sophisticated geometry of the Taguchi optimal designs are precisely fabricated. The performances of the coupling designs are validated using an experimental setup.

scholarly journals Experimental Optimization of Using Natural Pozzolan in Chloride Ion Exposed Concrete via Taguchi Method

2021 ◽  
Vol 15 (1) ◽  
pp. 69-75
Author(s):  
Amir Behshad ◽  
Mostafa Askarian Zardak ◽  
Yaser Mohammadi
Keyword(s):  
Taguchi Method ◽  
Water Absorption ◽  
Chloride Ion ◽  
Optimization Method ◽  
Mix Design ◽  
Natural Pozzolan ◽  
Taguchi Optimization ◽  
Taguchi Optimization Method ◽  
Oman Sea ◽  
Optimal Mix

Concrete durability is one of the most important concerns in the field of construction. The environmentally friendly materials that can provide the durability are of great value in the construction of concrete structures. The use of natural pozzolans is one of the cheapest and most efficient methods in this field, which offers a good performance from environmental and economic point of view and satisfies required engineering parameters. In this study, the effect of using natural pozzolan in the manufacture of concrete exposed to sulfate and chloride ion of Oman sea water was investigated. The Taguchi optimization method was used to reduce the number of samples prepared, reduce the cost of experiments and achieve an optimal mix design. The four parameters, namely water to cement ratio, different percentages of natural pozzolan, super-plasticizer and cement grade with different ratios, were considered as problem variables. The Taguchi optimization method proposed 8 mix designs based on the defined levels for the variables. By constructing 96 samples, two parameters of permeability and water absorption from Oman Sea and drinking water were investigated in the samples. By introducing the results of the experiments into the Taguchi method, the final optimal design was presented by this method, and by constructing 12 additional samples and conducting permeability and water absorption experiments, the behavior of this optimal mix design was verified. The appropriate performance of the Taguchi method was demonstrated by obtaining the optimal mix designs from the Taguchi method, constructing this mix design and comparing the results with the regulation limitations. The results showed that it is acceptable to use natural pozzolan under moderate to severe chloride and sulfate ion attacks, but it is not recommended in the extreme environmental conditions.

scholarly journals Analysis and Optimization of Tooth Surface Contact Stress of Gears with Tooth Profile Deviations, Meshing Errors and Lead Crowning Modifications Based on Finite Element Method and Taguchi Method

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1370
Author(s):  
Qiang Li ◽  
Liyang Xie
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Taguchi Method ◽  
Contact Stress ◽  
Influence Factors ◽  
Optimal Combination ◽  
Tooth Surface ◽  
Single Factor ◽  
Fem Model ◽  
Influence Degree

Based on the three-dimensional (3D) finite element method (FEM) and Taguchi method (TM), this paper analyzes the tooth surface contact stress (TSCS) of spur gears with three different influence factors: tooth profile deviations (TPD), meshing errors (ME) and lead crowning modifications (LCM), especially researching and analyzing the interactions between TPD, ME and LCM and their degree of influence on the TSCS. In this paper, firstly, a 3D FEM model of one pair of engaged teeth is modeled and the mesh of the contact area is refined by FEM software. In the model, the refined area mesh and the non-refined area mesh are connected by multi-point constraint (MPC); at the same time, in order to save the time of the FEM solution on the premise of ensuring the solution’s accuracy, the reasonable size of the refined area is studied and confirmed. Secondly, the TSCS analyses of gears with one single influence factor (other factors are all ideal) are carried out. By inputting the values of different levels of one single factor into the FEM model, especially using the real measurement data of TPD, and conducting the TSCS analysis under different torques, the influence degree of one single factor on TSCS is discussed by comparing the ideal model, and it is found that when the influence factors exist alone, each factor has a great influence on the TSCS. Finally, through TM, an orthogonal test is designed for the three influence factors. According to the test results, the interactions between the influence factors and the influence degree of the factors on the TSCS are analyzed when the three factors exist on the gear at the same time, and it is found that the TPD has the greatest influence on the TSCS, followed by the lead crowning modified quantity. The ME is relatively much small, and there is obvious interaction between ME and LCM. In addition, the optimal combination of factor levels is determined, and compared with the original combination of a gear factory, we see that the contact fatigue performance of the gear with the optimal combination is much better. The research of this paper has a certain reference significance for the control of TPD, ME and LCM when machining and assembling the gears.

scholarly journals Movable Die and Loading Path Design in Tube Hydroforming of Irregular Bellows

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1518
Author(s):  
Yeong-Maw Hwang ◽  
Yau-Jiun Tsai
Keyword(s):  
Tube Hydroforming ◽  
Simulation Software ◽  
Die Design ◽  
Loading Path ◽  
Feeding Types ◽  
Element Simulation ◽  
Hydroforming Process ◽  
Formed Product ◽  
Loading Path Design ◽  
Deform 3D

Manufacturing of irregular bellows with small corner radii and sharp angles is a challenge in tube hydroforming processes. Design of movable dies with an appropriate loading path is an alternative solution to obtain products with required geometrical and dimensional specifications. In this paper, a tube hydroforming process using a novel movable die design is developed to decrease the internal pressure and the maximal thinning ratio in the formed product. Two kinds of feeding types are proposed to make the maximal thinning ratio in the formed bellows as small as possible. A finite element simulation software “DEFORM 3D” is used to analyze the plastic deformation of the tube within the die cavity using the proposed movable die design. Forming windows for sound products using different feeding types are also investigated. Finally, tube hydroforming experiments of irregular bellows are conducted and experimental thickness distributions of the products are compared with the simulation results to validate the analytical modeling with the proposed movable die concept.

Performance optimization of a flexible manufacturing system using simulation: the Taguchi method versus OptQuest

SIMULATION ◽  
2019 ◽  
Vol 95 (11) ◽  
pp. 1085-1096 ◽  
Author(s):  
Abdessalem Jerbi ◽  
Achraf Ammar ◽  
Mohamed Krid ◽  
Bashir Salah
Keyword(s):  
Taguchi Method ◽  
Performance Optimization ◽  
Flexible Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Flexible Manufacturing System ◽  
Flow Time ◽  
Mean Flow ◽  
Taguchi Optimization ◽  
Mean Flow Time

The Taguchi method is widely used in the field of manufacturing systems performance simulation and improvement. On the other hand, Arena/OptQuest is one of the most efficient contemporary simulation/optimization software tools. The objective of this paper is to evaluate and compare these two tools applied to a flexible manufacturing system performance optimization context, based on simulation. The principal purpose of this comparison is to determine their performances based on the quality of the obtained results and the gain in the simulation effort. The results of the comparison, applied to a flexible manufacturing system mean flow time optimization, show that the Arena/OptQuest optimization platform outperforms the Taguchi optimization method. Indeed, the Arena/OptQuest permits one, through the lowest experimental effort, to reliably minimize the mean flow time of the studied flexible manufacturing system more than the Taguchi method.

Surface Roughness and Chip Formation of AlSi/AIN Metal Matrix Composite by End Milling Machining using the Taguchi Method

2014 ◽  
Vol 68 (4) ◽  
Author(s):  
M. S. Said ◽  
J. A. Ghani ◽  
R. Othman ◽  
M. A. Selamat ◽  
N. N. Wan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Matrix Composite ◽  
Surface Finish ◽  
Chip Formation ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Taguchi Optimization ◽  
Cutting Speeds

The purpose of this research is to demonstrate surface roughness and chip formation by the machining of Aluminium silicon alloy (AlSic) matrix composite, reinforced with aluminium nitride (AlN), with three types of carbide inserts present. Experiments were conducted at various cutting speeds, feed rates, and depths of cut, according to the Taguchi method, using a standard orthogonal array L9 (34). The effects of cutting speeds, feed rates, depths of cut, and types of tool on surface roughness during the milling operation were evaluated using Taguchi optimization methodology, using the signal-to-noise (S/N) ratio. The surface finish produced is very important in determining whether the quality of the machined part is within specification and permissible tolerance limits. It is understood that chip formation is a fundamental element that influences tool performance. The analysis of chip formation was done using a Sometech SV-35 video microscope. The analysis of results, using the S/N ratio, concluded that a combination of low feed rate, low depth of cut, medium cutting speed, and an uncoated tool, gave a remarkable surface finish. The chips formed from the experiment varied from semi–continuous to discontinuous. 

Numerical Simulation and Optimization of a Tee Shaped Tube Hydroforming Process

2006 ◽  
Author(s):  
J. Crapps ◽  
H. Fang ◽  
M. F. Horstemeyer
Keyword(s):  
Multiobjective Optimization ◽  
Tube Hydroforming ◽  
Industrial Process ◽  
Material Model ◽  
Simulation And Optimization ◽  
History Effects ◽  
Shaped Tube ◽  
Hydroforming Process ◽  
Optimization Methodology ◽  
Using Data

We performed numerical simulations and multiobjective optimization of a hydroforming process for copper tees using the BCJ plasticity material model developed by Bammann et al., which accounts for material manufacturing and history effects. A finite element simulation of the hydroforming process was created using data from experiments and the industrial process. The process parameters and geometry factors were optimized using a multiobjective optimization methodology employing metamodeling and software developed at Mississippi State University’s Center for Advanced Vehicular Systems.

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