Blank Shape Optimization Considering 3D Space Targets for External and Internal Boundaries in Sheet Metal Forming Processes

Optimum design of the shape of the initial blank is an important task before sheet metal forming processes. It reduces production costs, material waste and improves the quality of the product significantly. In the present work, the blank shape optimization problem is considered based on the 3D space...

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Published inTransactions of the Indian Institute of Metals Vol. 74; no. 8; pp. 2057 - 2072
Main Authors Gharehchahi, Hamidreza, Kazemzadeh-Parsi, Mohammad Javad, Afsari, Ahmad, Mohammadi, Mehrdad
Format Journal Article
LanguageEnglish
Published New Delhi Springer India 01.08.2021
Springer Nature B.V
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ISSN0972-2815
0975-1645
DOI10.1007/s12666-021-02311-9

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Abstract Optimum design of the shape of the initial blank is an important task before sheet metal forming processes. It reduces production costs, material waste and improves the quality of the product significantly. In the present work, the blank shape optimization problem is considered based on the 3D space target contours and moreover the sheet metal can have an internal boundary. In other words, the shape optimization process can be applied on the internal boundary, external boundary or both. To the best knowledge of the authors, there are no published works in this subject. Using the iterative simulation-based optimization process, a special shape error index and also updating algorithm were proposed to modify the blank geometry in each iteration until capturing the optimum shape. The sheet forming process is highly nonlinear in nature due to plastic behaviors, large deformations and frictional contact surfaces. Therefore, the updating formula should be robust enough to have less sensitivity with respect to the initial guess. To evaluate the proposed updating formula and its robustness, some numerical examples were considered and the effects of different tools geometries, 2D and 3D target contours, internal and external boundaries and different initial guesses were examined.
AbstractList Optimum design of the shape of the initial blank is an important task before sheet metal forming processes. It reduces production costs, material waste and improves the quality of the product significantly. In the present work, the blank shape optimization problem is considered based on the 3D space target contours and moreover the sheet metal can have an internal boundary. In other words, the shape optimization process can be applied on the internal boundary, external boundary or both. To the best knowledge of the authors, there are no published works in this subject. Using the iterative simulation-based optimization process, a special shape error index and also updating algorithm were proposed to modify the blank geometry in each iteration until capturing the optimum shape. The sheet forming process is highly nonlinear in nature due to plastic behaviors, large deformations and frictional contact surfaces. Therefore, the updating formula should be robust enough to have less sensitivity with respect to the initial guess. To evaluate the proposed updating formula and its robustness, some numerical examples were considered and the effects of different tools geometries, 2D and 3D target contours, internal and external boundaries and different initial guesses were examined.
Author Afsari, Ahmad
Kazemzadeh-Parsi, Mohammad Javad
Mohammadi, Mehrdad
Gharehchahi, Hamidreza
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Snippet Optimum design of the shape of the initial blank is an important task before sheet metal forming processes. It reduces production costs, material waste and...
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SubjectTerms Algorithms
Boundaries
Chemistry and Materials Science
Contours
Corrosion and Coatings
Iterative methods
Materials Science
Metal forming
Metal sheets
Metallic Materials
Optimization
Original Article
Production costs
Robustness (mathematics)
Shape optimization
Tribology
Title Blank Shape Optimization Considering 3D Space Targets for External and Internal Boundaries in Sheet Metal Forming Processes
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