Experimental Investigations and Automatic Numerical Optimization of a Bulk Metal Forming Process to Avoid Forging Folds

2015 ◽  
Vol 651-653 ◽  
pp. 305-310
Author(s):  
Bernd Arno Behrens ◽  
Sonda Moakhar Bouguecha ◽  
Milan Vucetic ◽  
Anas Bouguecha ◽  
Mohammad Kazhai
Keyword(s):  
Process Parameters ◽  
Process Design ◽  
Numerical Optimization ◽  
Experimental Investigations ◽  
Forming Process ◽  
Element Analysis ◽  
Complex Processes ◽  
Metal Forming Process ◽  
Fold Formation ◽  
Indispensable Tool

The detection of process failures in earlier design stages is essential for preventing high additional costs and a loss of time. Here, the finite element analysis (FEA) is an inherent part of the process design. This work represents numerical and experimental investigations, which were carried out in order to identify factors that influence the fold formation in an upsetting process of hollow parts, i.e. different forging velocities, different materials or the friction. The experimental results were compared with the numerical simulations. Based on these investigations, an automatic optimization model was created, which is the focus of this work. It allows varying and optimizing the experimentally determined process parameters, influencing the fold formation, automatically with the aim to produce a workpiece free of folds. For this purpose the commercial Software-System Forge (Transvalor) was used. The results of this work provide basic information for the development of complex processes. It can be shown that the automatic numerical optimization is an indispensable tool for the process design. It helps determining optimal process parameters individually and avoiding extensive trial and error investigations and hence a loss of time and costs.

On Applying Kriging Approximate Optimization to Sheet Metal Forming

2011 ◽  
Vol 63-64 ◽  
pp. 3-7
Author(s):  
Yan Min Xie
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Nonlinear Function ◽  
Kriging Model ◽  
Engineering Problem ◽  
Forming Process ◽  
Element Analysis ◽  
Metal Forming Process

This paper presents a methodology to effectively determine the optimal process parameters using finite element analysis (FEA) and design of experiments (DOE) based on Metamodels. The idea is to establish an approximation function relationship between quality objectives and process parameters to alleviate the expensive computational expense in the optimization iterations for the sheet metal forming process. This paper investigated the Kriging metamodel approach. In order to prove accuracy and efficiency of Kriging method, the nonlinear function as test functions is implemented. At the same time, the practical nonlinear engineering problems such as square drawing are also optimized successfully by proposed method. The results prove Kriging model is an effective method for nonlinear engineering problem in practice.

Reduction of Stages in Multi-Stage Metal Forming Process Based on Numerical Optimization in Conjunction with FE Simulation

2007 ◽  
Vol 340-341 ◽  
pp. 767-772
Author(s):  
Ryutaro Hino ◽  
Akihiko Sasaki ◽  
Fusahito Yoshida ◽  
Vassili V. Toropov
Keyword(s):  
Design Optimization ◽  
Process Design ◽  
Metal Forming ◽  
Numerical Optimization ◽  
Fe Simulation ◽  
Design Technique ◽  
Forming Process ◽  
Multi Stage ◽  
Metal Forming Process ◽  
Stage Process

In this study, a new simulation-based design technique for multi-stage metal forming process is developed with special emphasis on reduction of stages in the process. The developed design technique is an iterative design optimization, which is based on response-surface-based numerical optimization and finite element analysis of the process. The design procedure starts with the initial rough process design. To eliminate one stage in the multi-stage process, the new optimum process design is determined based on the former process design by using numerical optimization in conjunction with FE simulation. This design optimization step is repeated, reducing the stages one by one, until the possible minimum number of stages is reached. The developed design technique is applied to stage reduction of a 3-stage axisymmetric forging process of aluminum billet. We can confirm that a new 2-stage process design is determined successfully and the developed design optimization technique is effective to reduce stages in multi-stage forming process.

Research on the Metal Forming Process of the Muffler Tube Using Finite Element Method

2008 ◽  
Vol 385-387 ◽  
pp. 841-844
Author(s):  
Kyu Taek Han ◽  
Yi Jiong Jin
Keyword(s):  
Finite Element ◽  
Process Design ◽  
Metal Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Punch Radius ◽  
Metal Forming Process ◽  
Fracture Theory ◽  
Simulation Results ◽  
Fourth Component

A muffler is an important part used to reduce noise and to purify exhaust gas in cars and heavy equipments. Recently there has been a growing interest in the designing and manufacturing the muffler tube due to the strict environmental regulations. The technique of perforating on the muffler tube has been largely affected by the shear clearance. And considering the concentration of the force around the punch edge, it is essential to reduced it through the punch radius. In this research, finite element analysis has been carried out to predict optimal forming conditions of the muffler tube using DEFORMTM-3D. In analysis, using one-fourth component of the punch and die, metal forming process is simulated and Cockcroft-Latham ductile fracture theory is used. According to the simulation results, when the shear clearance is 0.04mm, the punch radius is 0.05mm and the value of plate holder force is 250KN, the relation of load-stroke for punch is optimized. Also the burr is minimized and optimal shear section is obtained. The simulation results are reflected to the forming process design for the muffler tube.

Multi-Objective Optimal Approach Based on Kriging Model in a Deep Drawing Process

2011 ◽  
Vol 474-476 ◽  
pp. 205-210 ◽  
Author(s):  
Yan Min Xie
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Nonlinear Function ◽  
Kriging Model ◽  
Forming Process ◽  
Element Analysis ◽  
Metal Forming Process ◽  
Proper Design ◽  
Function Relationship ◽  
Optimal Approach

Sheet metal stamping processes design is not a trivial task due to the complex issues to be taken into account. Therefore, proper design methodologies to reduce times and costs have to be developed mostly based on computer aided procedures. This paper presents a methodology to effectively determine the optimal process parameters using finite element analysis (FEA) and design of experiments (DOE) based on Metamodels. The idea is to establish an approximation function relationship between quality objectives and process parameters to alleviate the expensive computational expense in the optimization iterations for the sheet metal forming process. This paper investigated the Kriging metamodel approach. In order to prove accuracy and efficiency of Kriging method, a nonlinear function as test functions is implemented. At the same time, the practical nonlinear engineering problems such as square drawing are also optimized successfully by proposed method.

A Knowledge-Based Engineering Method to Integrate Metal Forming Process Design and Simulation

1994 ◽  
Author(s):  
Tom Robertson ◽  
Biren Prasad ◽  
Ravi Duggirala
Keyword(s):  
Process Design ◽  
Metal Forming ◽  
Computer Aided Design ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Simulation ◽  
Knowledge Based ◽  
Metal Forming Process ◽  
Knowledge Based Engineering ◽  
Integrate Design

Abstract The integration of Computer Aided Design (CAD) and Finite Element Analysis (FEA) tools is an important consideration in metal forming design. Traditionally, engineering functions such as classical analysis, FEA, CAD, etc. are performed separately. The emergence of knowledge-based engineering (KBE) tools and its language-based structure provides a basis to integrate design functions. This paper presents a KBE system which effectively integrates metal forming process design and FEA analysis by automating the pre-processing required for metal forming simulation for two dimensional problems. The method will be applicable to 3D problems as FEA technology improves.

Numerical and Experimental Investigations of Multistage Sheet-Bulk Metal Forming Process with Compound Press Tools

2015 ◽  
Vol 651-653 ◽  
pp. 1153-1158 ◽  
Author(s):  
Bernd Arno Behrens ◽  
Anas Bouguecha ◽  
Milan Vucetic ◽  
Sven Hübner ◽  
Daniel Rosenbusch ◽  
...  
Keyword(s):  
Metal Forming ◽  
Solid Metal ◽  
Experimental Investigations ◽  
Metal Component ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Process Sequence ◽  
Metal Forming Process ◽  
Flange Forming

Sheet-bulk metal forming is a manufacturing technology, which allows to produce a solid metal component out of a flat sheet. This paper focuses on numerical and experimental investigations of a new multistage forming process with compound press tools. The complete process sequence for the production of this solid metal component consists of three forming stages, which include a total of six production techniques. The first forming stage includes deep drawing, simultaneous cutting and following wall upsetting. In the second forming stage, flange forming combined with cup bottom ironing takes place. In the last stage of the process sequence, the component is sized. To investigate and to improve process parameters such as plastic strain distribution, resulting dimensions and process forces, FEA is performed. Based on these results the developed process is designed.

Prediction and Optimization of Deformations in Coupling Mechanism Based Laser Forming of Sheet Metals

2019 ◽  
Vol 969 ◽  
pp. 552-557
Author(s):  
Kuntal Maji
Keyword(s):  
Process Parameters ◽  
Metal Forming ◽  
Three Dimensional ◽  
Laser Forming ◽  
Coupling Mechanism ◽  
Sheet Metals ◽  
Forming Process ◽  
Out Of Plane ◽  
Metal Forming Process ◽  
Plane Deformations

Fabricating three dimensional shaped surfaces from flat sheet metals by laser forming, both out-of-plane and in-plane deformations are required. This article presents the modeling of coupling mechanism activated laser forming of sheet metals based on experimental data for prediction and optimization of bending and thickening deformations. Experiments were performed based on a central composite design of experiments on coupling mechanism based laser metal forming process considering the input process parameters like laser power, scan speed and spot diameter, bending and thickening were taken as the outputs. Neural network and neuro-fuzzy system-based models were developed to carry out both forward and inverse modeling of the laser metal forming process under the coupling mechanism. Multi-objective optimization based on the non-dominated sorting genetic algorithm was used to obtain multiple optimal solutions to achieve different amounts of out-of-plane and in-plane deformations. The proposed method could guide for a suitable selection of the process parameters to produce three-dimensional shapes utilizing coupling mechanism-based laser forming using multiple laser line heating.

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