Numerical and experimental case study on simultaneous optimization of blank shape and variable blank holder force trajectory in deep drawing
Numerical and experimental case study on simultaneous optimization of blank shape and variable blank holder force trajectory in deep drawing
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DOI：
10.1007/s00158-016-1484-4
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发表时间：
2017
影响因子：
3.9
通讯作者：
S. Kitayama;H. Koyama;K. Kawamoto;T. Noda;Ken Yamamichi;Takuji Miyasaka
中科院分区：
文献类型：
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作者：
S. Kitayama;H. Koyama;K. Kawamoto;T. Noda;Ken Yamamichi;Takuji Miyasaka
本文以深拉深成形过程中坯料形状和变压边力轨迹的同步优化为例进行了研究，这是钣金成形工业中的难题之一。毛坯形状直接影响材料成本。为了降低材料成本，确定一个最佳的毛坯形状是很重要的。此外，VBHF方法被认为是成功成形板材的一种有吸引力的关键技术，但实际应用很少报道。为了解决这些问题，对毛坯形状和VBHF轨迹进行了同步优化。首先，进行起皱区域识别实验。在试验结果的基础上，建立了有限元分析模型。利用FLD检验了有限元模型的有效性。深拉深过程的数值模拟非常密集，因此采用径向基函数（RBF）网络的顺序近似优化（SAO）方法进行数值优化。在此基础上，利用交流伺服压力机进行了实验研究。实验结果表明，成功地进行了板料成形。此外，数值和实验结果证实，采用优化设计技术可以同时降低材料成本和成形能量。
This paper shows a case study for a simultaneous optimization of blank shape and variable blank holder force (VBHF) trajectory in deep drawing, which is one of the challenging issues in sheet metal forming in industry. Blank shape directly affects the material cost. To reduce the material cost, it is important to determine an optimal blank shape minimizing earing. In addition, VBHF approach is recognized as an attractive and crucial technology for successful sheet metal forming, but the practical application is rarely reported. To resolve these issues, the simultaneous optimization of blank shape and VBHF trajectory is performed. First, the experiment to identify the wrinkling region is carried out. Based on the experimental results, the finite element analysis (FEA) model is developed. The validity of the FEA model is examined by using the FLD. Numerical simulation in deep drawing is so intensive that a sequential approximate optimization (SAO) using a radial basis function (RBF) network is used for the numerical optimization. Based on the numerical result, the experiment using the AC servo press is carried out. It is found from the experimental results that the successful sheet metal forming is performed. In addition, it is confirmed from the numerical and experimental result that both the material cost and the forming energy are simultaneously reduced by using the design optimization technique.