Automated design methodology for automobile side panel die using an effective optimization approach

Kayabaşı, Oğuz; Eki̇ci̇, Bülent

doi:10.1016/j.matdes.2006.10.011

Cited by 26 publications

(7 citation statements)

References 12 publications

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“…This significantly improves the performance of the GA method by reducing the number of function evaluations. The approach is significantly different from the earlier multi‐objective optimization studies in sheet metal forming where response surface methodology was utilized to evaluate the objective functions …”

Section: Solution Strategymentioning

confidence: 98%

Multi‐Objective Genetic Algorithm to Optimize Variable Drawbead Geometry for Tailor Welded Blanks Made of Dissimilar Steels

Hariharan

Nguyen

Chakraborti

et al. 2014

steel research int.

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Formability of a tailor welded blank (TWB) is affected by the strength ratio of the base metals joined. In this paper, formability of TWB with very high strength ratio made by joining twinning-induced plasticity (TWIP) and low carbon steels is numerically studied using a limiting dome height test. The drawbead geometry at the weaker side is modified to increase the dome height. The design of drawbead is optimized by treating it as a multi-objective problem with maximum dome height and minimum weldline movement as objectives, which were constructed as metamodels through a genetic algorithms based approach. The necessary data for the metamodeling are generated by finite element (FE) simulation using the commercial solver, LS-DYNA 1 . The multi-objective optimization is carried out using a predator-prey genetic algorithm. The Pareto front estimated using this evolutionary approach is validated using FE simulations and a good correlation is obtained. Figure 14. FLD of optimal case (a) without drawbead transition (b) with drawbead transition. www.steel-research.de 1606 steel research int. 85 (2014) No. 12

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Section: Solution Strategymentioning

confidence: 98%

Multi‐Objective Genetic Algorithm to Optimize Variable Drawbead Geometry for Tailor Welded Blanks Made of Dissimilar Steels

Hariharan

Nguyen

Chakraborti

et al. 2014

steel research int.

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“…Numerical simulations have become a powerful instrument for process optimization owing to their ability to predict the behavior of the material during deformation accurately. Various optimization techniques have been employed to identify the optimal process parameters, such as GA, ANNs and RSM [21,22,23]. Additionally, studies focused on the development of optimization frameworks to reduce specific defects, for instance, failure, wrinkling and springback, which are the most commonly observed defects in the metal forming process [24,25,26].…”

Section: Literature Reviewmentioning

confidence: 99%

Numerical multi-objective optimization of segmented and variable blank holder force trajectories in deep drawing based on DNN-GA-MCS strategy

Guo¹,

Jeong²,

Park³

et al. 2023

Preprint

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This research introduces a novel methodology for mitigating defects in sheet metal forming processes. The proposed approach employs a segmented and variable blank holder force (S-VBHF) trajectory, adjusting the blank holder force (BHF) during the forming cycle, enhancing formability, and reducing failure, wrinkling and springback defects. Optimal process parameters, including the S-VBHF, friction coefficient and drawbead restraining force (DBRF), were determined through a systematic methodology integrating deep neural network, genetic algorithm and Monte Carlo simulation (DNN-GA-MCS) techniques. The design constraint, defined as sheet failure during the forming process, was quantitatively evaluated using the forming limit diagram (FLD) to ensure rigorous assessment. The proposed methodology was validated through numerical simulations using a cylindrical cup provided by NUMISHEET 2011 (BM1) as test samples. The simulation results demonstrated a significant improvement in the formed sheet quality, characterized by reductions of 8.33%, 10.81% and 5.88% in failure, wrinkling and springback defects, respectively. These findings underscore the potential of the proposed approach in enhancing the quality of sheet metal forming processes and mitigating defects.

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“…At present, a great deal of research mainly focus on the drawing process forming parameters and process profile design [9]. Kayabasi et al [10] studied the use of finite element analysis to optimize the process parameters of automobile covering parts to improve the format. The position of the upper die and the drawbead, the radius of the drawbead and the force acting on the upper die surface are chosen as the process parameters to be optimized.…”

Section: Related Workmentioning

confidence: 99%

Research on automatic analysis and layout system of the stamping process for automotive panels and its key technologies

Kong,

Lei,

Chao

et al. 2023

Int J Adv Manuf Technol

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The stamping process analysis and layout of automotive panels are extremely complex and time-consuming, which directly affects the quality and cycle of product development. Based on the CAGD theory of complex curves and surfaces, process design knowledge, and multidisciplinary optimization techniques, an intelligent automatic process analysis and layout system has been developed. The process feature analysis method based on discretization and merging idea has been proposed to accurately and automatically identify process features such as piercing, trimming, flanging and restricting. The process feature dispersion method based on curvature and normal variation of the forming surface is proposed to ensure the accuracy of feature dispersion. The combinatorial optimization algorithm is proposed to merge the discrete features according to the stamping direction and the geometric parameters of the features to reduce the number of process steps as much as possible. Moreover, a process constraint diagram with combined features is constructed, which is used as the initial solution and sequence constraint conditions for the process layout to effectively ensure the rationality of the process layout. Based on the die design rules, the simplified tools of the process features are created, and the rapid interference detection algorithm of the tools is proposed to realize the automatic layout and optimization of the stamping process. Finally, the aforementioned algorithms are seamlessly integrated into the NX software to develop an automatic analysis and layout system for the automotive panel stamping process. The feasibility, accuracy and efficiency of the system have been demonstrated through the example of the wing panel and the system has been successfully applied in enterprises.

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Automated design methodology for automobile side panel die using an effective optimization approach

Cited by 26 publications

References 12 publications

Multi‐Objective Genetic Algorithm to Optimize Variable Drawbead Geometry for Tailor Welded Blanks Made of Dissimilar Steels

Multi‐Objective Genetic Algorithm to Optimize Variable Drawbead Geometry for Tailor Welded Blanks Made of Dissimilar Steels

Numerical multi-objective optimization of segmented and variable blank holder force trajectories in deep drawing based on DNN-GA-MCS strategy

Research on automatic analysis and layout system of the stamping process for automotive panels and its key technologies

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