Optimisation of Tubular Hydroforming Processes for Wrinkling and Thinning Control

Abstract:

This paper is focused on the development and implementation of an innovative optimisation algorithm for the wrinkling and thinning control during the hydroforming of complex metallic parts. A straightforward numerical algorithm for simultaneous tracking and evaluation of the initiation of wrinkling/thinning defects was implemented, together with a numerical simulation program based on the Finite Element Method (FEM). After undesirable wrinkling/thinning patterns are identified during FEM simulation, the developed optimisation procedure (called Hybrid Differential Evolution Particle Swarm Optimisation - HDEPSO) is responsible to automatically correct the process input parameters, in order to achieve the successful forming of the desired part. In the end, the combined procedure (optimisation methodology + FEM) proved to be able to lead to a suitable numerical simulation and design tool for industrial hydroformed metallic tubular parts.

• Periodical: Key Engineering Materials (Volume 473)
• Pages: 159-167
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.473.159
• Online since: March 2011
• Authors: João F.M. Caseiro, Robertt Valente, António Andrade-Campos, Renato Natal Jorge
• Keywords: Finite Element Model (FEM), Hydroforming, Optimization, Thinning, Wrinkling

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