Sensitivity Analysis for Numerical Sheet Metal Forming Processes

Abstract:

Sheet Metal Forming is a widely used process in industry. However, it is also an expensive onedue to the diversity and complexity of methodologies used to obtain the adequate tools combination.In fact, even though there is already finite element based software to compute the final shape of aformed sheet from a given tool, there is no efficient procedure to predict the inverse problem: the toolgeometry from the formed component final shape.The final aim of this work is to improve the current trial-and-error process for the inverse problem.To achieve this objective, an integrated approach for tools geometry manipulation is presented, basedon the parametric NURBS description of the tools surface. This is applied to perform a sensitivityanalysis in order to evaluate the effect of numerical noise and small disturbances on the tools designvariables in the final formed sheet. Furthermore, the robustness of the proposed approach is evaluatedusing two parts with distinct complexity.

• Periodical: Key Engineering Materials (Volumes 651-653)
• Pages: 1369-1374
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.651-653.1369
• Online since: July 2015
• Authors: Ana Maia*, Marta C. Oliveira, António Andrade-Campos, Luís F. Menezes
• Keywords: IGES, Integrated Process, Metal Sheet Forming, NURBS, Tool Design

References

[1] L.F. Menezes and C. Teodosiu: Three-dimensional numerical simulation of the deep-drawing process using solid finite elements, Journal of Materials Processing Technology, vol. 97, no. 1-3, pp.100-106, Jan (2000).

DOI: 10.1016/s0924-0136(99)00345-3

[2] P. Picart, O. Ghouati and J.C. Gelin, Optimization of metal forming process parameters with damage minimization, Journal of Materials Processing Technology, vol. 80-81, pp.597-601, Aug (1998).

DOI: 10.1016/s0924-0136(98)00167-8

[3] F. van Keulen, R.T. Haftka and N.H. Kim: Review of options for structural design sensitivity analysis. Part 1: Linear systems, Computer Methods in Applied Mechanics and Engineering, vol. 194, no. 30-33, Aug (2005).

DOI: 10.1016/j.cma.2005.02.002

[4] J.P. Ponthot, J.P. Kleinermann, A cascade optimization methodology for automatic parameter identification and shape/process optimization in metal forming simulation, Comput Methods Appl. Mech Engrg, vol. 195, pp.5472-5508, (2006).

DOI: 10.1016/j.cma.2005.11.012

[5] Wang Hu, Li Guang Yao and Zhong Zhi Hua: Optimization of sheet metal forming processes by adaptive response surface based on intelligent sampling method, Journal of Materials Processing Technology, vol. 197, no. 1-3, pp.77-88, Feb (2008).

DOI: 10.1016/j.jmatprotec.2007.06.018

[6] J.H. Wiebenga and A.H. van den Boogaard: On the effect of numerical noise in approximate optimization of forming processes using numerical simulations, Int J Mater Form, vol. 7, pp.317-335, Apr (2013).

DOI: 10.1007/s12289-013-1130-2

[7] Wiebenga JH, van den Boogaard AH, Klaseboer G: Sequential robust optimization of a v-bending process using numerical simulations, J Struct Multidisc Optim, vol. 46, pp.137-153, (2012).

DOI: 10.1007/s00158-012-0761-0

[8] D.M. Neto, M.C. Oliveira, L.F. Menezes and J.L. Alves: Nagata patch interpolation using surface nornal vectors evaluated from the IGES file, Finite Elements in Analysis and Design, vol. 72, pp.35-46, May (2013).

DOI: 10.1016/j.finel.2013.03.004