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Stiffening of cambered sheet metal designs: numeric bead optimization by a coupled algorithm considering nonlinear forming limits

弧形钣金设计的加固：通过考虑非线性成形极限的耦合算法进行数值焊道优化

基本信息

批准号：
254853550
负责人：
Professor Dr.-Ing. Albert Albers
金额：
--
依托单位：
Institut für Produktentwicklung (IPEK)
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2014
资助国家：
德国
起止时间：
2013-12-31 至 2017-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/254853550?language=en
关键词：
Stiffening cambered sheet metal designs

项目摘要

Beads are used in deep drawn sheet metal parts for increasing the part stiffness. Thus reductions of sheet metal thickness and consequently weight reduction can be reached. Style guides for types and positions of beads exist, which are often applied. However, higher stiffness effects can be realized using numeric optimization. Existing algorithms for the optimization of beads have disadvantages concerning the relationship between computing times and stiffening effect. Manufacturing processes as well as the geometry of the sheet metal part are also not taken into account sufficiently by these algorithms.Within this research project, an optimization method will be developed which combines the advantages of two different optimization strategies and furthermore considers the manufacturing process of cupping with an additional deep drawing of beads. The bead paths will be determined with a cost-efficient optimality criteria-based (OC) method, the bead profile parameters will be detected by a sensitivity-based optimization method. This combination of two different optimization strategies also allows the consideration of the maximum formability under justifiable computational costs.The optimization algorithm to be developed considers the two-stepped manufacturing process consisting of deep drawing and beading. The formability in both manufacturing steps represents a limiting factor. Considering nonlinear strain paths, acceptable geometry and process parameters will be determined in numerical and experimental tests. These will be integrated in the optimization algorithm. Furthermore the algorithm considers the effect of beads on the stiffness according to the camber of the deep drawn geometry. This will also be verified using simulation and experiment.

在深冲钣金件中使用卷边以增加零件刚度。因此，可以实现金属板厚度的减小以及因此重量的减轻。存在经常应用的用于珠子类型和位置的样式指南。然而，更高的刚度效果可以使用数值优化来实现。现有的算法优化珠有缺点的计算时间和加劲效果之间的关系。制造过程以及钣金件的几何形状也没有充分考虑这些algorithm.Within本研究项目，将开发一种优化方法，它结合了两种不同的优化策略的优势，并进一步考虑了制造过程中的杯形与一个额外的深拉延珠。微珠路径将通过基于成本效益的最优准则（OC）方法确定，微珠轮廓参数将通过基于灵敏度的优化方法检测。这两种不同的优化策略的组合还允许在合理的计算成本下考虑最大的可成形性。要开发的优化算法考虑了由拉深和卷边组成的两步制造工艺。两个制造步骤中的可成形性代表限制因素。考虑到非线性应变路径，可接受的几何形状和工艺参数将在数值和实验测试中确定。这些将被集成到优化算法中。此外，该算法还根据拉深件的曲面形状考虑了凸筋对拉深件刚度的影响。这也将通过模拟和实验来验证。