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Minimizing the risk of failure in a sheet metal forming process: optimization using space mapping with one-step and incremental solvers
Linköping University, Department of Management and Engineering, Solid Mechanics. Linköping University, The Institute of Technology.
Linköping University, Department of Management and Engineering, Solid Mechanics. Linköping University, The Institute of Technology.
2006 (English)In: Structural and multidisciplinary optimization (Print), ISSN 1615-147X, E-ISSN 1615-1488, Vol. 31, no 4, 320-332 p.Article in journal (Refereed) Published
Abstract [en]

In the present paper, an optimization technique has been used to minimize the risk of failure in a sheet metal forming process. Two different types of finite element solvers, one using total plasticity and the other using incremental plasticity, have been used. A comparison between response surface methodology and space mapping (SM) with the one-step solver as surrogate model has been done. The conclusion of this study is that the use of the total plasticity theory drastically reduces the required computing time. Furthermore, the solution from the SM optimization algorithm is close to the solution obtained by the incremental plasticity solver.

Place, publisher, year, edition, pages
2006. Vol. 31, no 4, 320-332 p.
Keyword [en]
Incremental solver, One-step solver, Response surface methodology, Sheet metal forming, Space mapping
National Category
Engineering and Technology
Identifiers
URN: urn:nbn:se:liu:diva-50249DOI: 10.1007/s00158-005-0604-3OAI: oai:DiVA.org:liu-50249DiVA: diva2:271145
Available from: 2009-10-11 Created: 2009-10-11 Last updated: 2017-12-12
In thesis
1. Optimization of sheet metal forming processes
Open this publication in new window or tab >>Optimization of sheet metal forming processes
2005 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The potential of using simulation and optimization techniques in the design of sheet metal forming processes has been investigated. Optimization has been used in a variety of sheet metal forming applications. This usage has given ideas and guidelines on how to formulate an optimization problems, how to ensure its rapid convergence and how to reach a feasible process design. Furthermore one method to include the uncertainty and variation in the governing parameters has been evaluated.

For each forming process many formability problems exist which usually are associated with fracture, wrinkling and springback. The aim of a good process design is to avoid these problems. By the use of simulation based design the physical trial- and error iterations can to a large extent be replaced by virtual iterations. When optimization techniques are used in the design process the number of iterations can be very large. In this work effort has been made to develop an optimization method, Space Mapping (SM), which is less computing intensive. It has been shown that SM can drastically reduce the required computing time and that its optimal solution is close to the optimal solution obtained by the more computing intensive Response Surface Methodology (RSM). The drawback of SM is that the method is less robust compared to RSM, and that it requires a better initial design for convergence.

Each industrial sheet metal forming process exhibits a certain degree of stochastic behavior due to uncertainties and variations in material properties, geometry and other process parameters. The forming process must be designed such that it is insensitive to these uncertainties and variations, i.e. the process must be robust. One possibility to consider uncer tainties and variations in a simulation and optimization based design process is to use the Monte Carlo method, in particular in combination with response surfaces as metamodels. It has been shown in this work that a linear response surface can successfully be used to identify the important design variables and to give an estimate of the probabilistic response. It has also been found that quadratic surfaces are required for a more accurate evaluation of the response.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2005. 34 p.
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 936
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-31401 (URN)17172 (Local ID)91-85297-74-7 (ISBN)17172 (Archive number)17172 (OAI)
Public defence
2005-05-13, C3, Hus C, Campus Valla, Linköpings Universitet, Linköping, 10:00 (Swedish)
Opponent
Available from: 2009-10-09 Created: 2009-10-09 Last updated: 2012-12-03Bibliographically approved

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Jansson, TomasNilsson, Larsgunnar

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