Advances in Production Engineering & Management
Volume 9 | Number 2 | June 2014 | pp 71–82
http://dx.doi.org/10.14743/apem2014.2.177
Determining the optimal area-dependent blank holder forces in deep drawing using the response surface method
Volk, M.; Nardin, B.; Dolsak, B.
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A B S T R A C T
Metal forming processes are often currently highly automated mass production processes for manufacturing a wide variety of metal parts from various industries. Maximizing product quality and consequently minimizing waste and production costs are major goals for those companies exploiting metal forming processes. On the other hand, sheet metal parts become more complex especially because of complex product designs and the usages of higher strength steels that have less formability. Therefore, metal forming processes need to be optimized. This research study demonstrates an optimization system for optimizing the sheet metal forming process using the Finite Element Method (FEM) combined with the Response Surface Method (RSM). The proposed optimization system was tested on an industrial example from the household appliances industry. In this study, it is described as to how to determine optimal area-dependent blank-holder forces in deep drawing process in order to obtain the best possible quality of the drawing part. The optimization system consists of three main steps: modeling, screening, and optimization. The results showed that with better preferences regarding the blank-holder forces, better results can be achieved. Forming and spring-back criteria were taken into account. The number of required numerical simulations using the RSM combined with the Design of Experiment was not critical and was much smaller than using other conventional optimization methods. Therefore, reasonably accurate results can be achieved in a relativity short time, which is one of the main advantages of this method.
A R T I C L E I N F O
Keywords • Sheet metal forming, Optimization, Finite element method, Response surface method
Corresponding author • Volk, M.
Article history • Received 6 December 2013, Revised 30 May 2014, Accepted 3 June 2014
Published on-line • 12 June 2014
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