Surrogate-based multi-point forming process optimization for dimpling and wrinkling reduction

Abebe, Misganaw; Lee, Kyung-Hoon; Kang, Beom-Soo

doi:10.1007/s00170-015-7897-1

Cited by 30 publications

(10 citation statements)

References 21 publications

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“…It was found that a thicker elastic cushion leads to geometrical errors in the fabricated part. Liu et al [7] studied the impact of cushion material, cushion thickness and coefficient of friction on surface quality in micro multipoint sheet forming and found that proper selection of elastic cushion material and thickness can significantly improve surface quality, especially when combined with using lubrication. Abebe et al [8] proposed surrogate-based multi-objective optimisation to reduce wrinkling and dimpling during the MPF process.…”

Section: Introductionmentioning

confidence: 99%

“…Liu et al [7] studied the impact of cushion material, cushion thickness and coefficient of friction on surface quality in micro multipoint sheet forming and found that proper selection of elastic cushion material and thickness can significantly improve surface quality, especially when combined with using lubrication. Abebe et al [8] proposed surrogate-based multi-objective optimisation to reduce wrinkling and dimpling during the MPF process. However, they did not consider uncertainties in factors such as material properties, friction at the interfaces and the workpiece thickness, which may deteriorate the quality of the workpiece during multi-point dieless forming.…”

Section: Introductionmentioning

confidence: 99%

“…In common with simulations of other sheet metal forming processes such as conventional deep drawing and stamping, an explicit solver was used to avoid convergence issues because the number of elements was high, and the contact problem was complicated [8,16].…”

Section: Introductionmentioning

confidence: 99%

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Optimisation of multi-point forming process parameters

Abosaf

Essa

Alghawail

et al. 2017

Int J Adv Manuf Technol

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The need for sheet metal forming using reconfigurable dies has increased due to rapid changes in part design to meet customer requirements, especially in the automotive industry. Reconfigurable dies have relatively low manufacturing cost compared with solid dies, and the same tool can be readily changed to produce different parts. Previous investigations have focused on avoiding defects without taking into account the effects of process on the quality characteristics of fabricated parts. This study investigated the influence of parameters, such as the elastic cushion thickness, coefficient of friction, pin size and radius of curvature, on the quality of parts formed in a flexible multi-point stamping die. The aim was to determine the optimum values of those parameters. Finite element modelling was employed to simulate the multi-point forming of hemispherical parts. Using the response surface method, the effects of process parameters on wrinkling, deviation from the target shape and thickness variation were investigated and the process parameters yielding the best product quality characteristics were obtained. The results show that pin size and radius of curvature have the greatest influence on wrinkling and deviation between formed and target shapes, while coefficient of friction, pin size and radius of curvature significantly affect thickness variation.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Optimisation of multi-point forming process parameters

Abosaf

Essa

Alghawail

et al. 2017

Int J Adv Manuf Technol

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“…The material properties are taken from our previous study [17], which is also mentioned in Table 1. Since the MDF process is a small deformation, the study treated the sheet material as an isotropic property, in addition, here, the MDF process is not subjected to cyclic loading so that the study chose isotropic hardening instead of kinematic hardening.…”

Section: Materials Modelmentioning

confidence: 99%

“…Finally, the implicit analysis was exploited to determine the succeeding springback displacement in the deformed blank that occurred after the forming load was removed. The FE simulation model was experimentally validated in our previous study [17,18]. …”

Section: Simulation Modelmentioning

confidence: 99%

Radial Basis Functional Model of Multi-Point Dieless Forming Process for Springback Reduction and Compensation

Abebe

Yoon

Kang

2017

Metals

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Springback in multi-point dieless forming (MDF) is a common problem because of the small deformation and blank holder free boundary condition. Numerical simulations are widely used in sheet metal forming to predict the springback. However, the computational time in using the numerical tools is time costly to find the optimal process parameters value. This study proposes radial basis function (RBF) to replace the numerical simulation model by using statistical analyses that are based on a design of experiment (DOE). Punch holding time, blank thickness, and curvature radius are chosen as effective process parameters for determining the springback. The Latin hypercube DOE method facilitates statistical analyses and the extraction of a prediction model in the experimental process parameter domain. Finite element (FE) simulation model is conducted in the ABAQUS commercial software to generate the springback responses of the training and testing samples. The genetic algorithm is applied to find the optimal value for reducing and compensating the induced springback for the different blank thicknesses using the developed RBF prediction model. Finally, the RBF numerical result is verified by comparing with the FE simulation result of the optimal process parameters and both results show that the springback is almost negligible from the target shape.

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