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Optimization of drawbead design in sheet forming using one step finite element method coupled with response surface methodology

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Abstract

In a sheet forming process, drawbead plays an important role on the control of the material flow. In this paper, a numerical procedure for the design of forming processes is described. It is based on the coupling of an optimization technique and the simplified one step finite element method (also called inverse approach). The optimization technique allows adjustment of the process parameters so that specified criteria are fulfilled. Response surface methodology (RSM) is a global approximation method, which is ideally suited for solving highly nonlinear optimization problems. The finite element method, in addition to predicting the response of the process to certain parameters, allows assessment of the effect of a variation in these parameters on this response. The authors utilize the one step method at the preliminary design stage to supply stress or strain information for the following optimization using RSM. The procedure for this optimization process is fully described. The front fender for Numisheet 2002 is presented and the real defect free workpiece is produced to demonstrate the usefulness of the proposed optimization procedure. A comparison between the two forming limit curves (FLC) before and after optimization and results obtained using the precise incremental commercial software DYNAFORM based on the explicit dynamic approach verify that the optimization design method of drawbead could be successfully applied in designing actual tools of auto body cover panels.

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Abbreviations

RSM:

Response surface methodology

FLC:

Forming limit curve

IA:

Inverse approach

SQP:

Sequential quadratic programming

PIA:

Pseudo inverse approach

AFSD:

Automatic forging sequence design

PVW:

Principle of virtual work

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Authors and Affiliations

  1. Department of Plasticity Technology, Shanghai Jiaotong University, 1954 Huashan Road, Shanghai, 200030, People’s Republic of China

    Bingtao Tang, Jixian Sun, Zhen Zhao, Jun Chen & Xueyu Ruan

Authors
  1. Bingtao Tang
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  2. Jixian Sun
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  3. Zhen Zhao
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  4. Jun Chen
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  5. Xueyu Ruan
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Correspondence to Zhen Zhao.

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Tang, B., Sun, J., Zhao, Z. et al. Optimization of drawbead design in sheet forming using one step finite element method coupled with response surface methodology. Int J Adv Manuf Technol 31, 225–234 (2006). https://doi.org/10.1007/s00170-005-0208-5

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  • DOI: https://doi.org/10.1007/s00170-005-0208-5

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