Optimization of Stamping Process Parameters

Abstract

Stamping is one of the significant sheet metal forming processes which is used for producing components especially in the automobile industry. Sheet metal flow into the die cavity occurs the applied force in the stamping process. While the extreme compressive stresses of sheet metal end up with wall thickening, tensile stresses lead to thinning problems in the wall zone of the part. The excessive thinning may cause crack formation or fracture of the metal sheet. This faulty process design eventually produces non-conforming products. In order to have a successful design of the stamping process, designing tooling and identification of the optimum level of the process parameters are needed. In this regard, the present paper is an attempt to set the stamping process parameters for minimum thinning of blank and optimal results by a stochastic search method (modified Differential Evolution) based on multiple nonlinear regression analysis. The results have been compared with the results of those of the previous study. It is shown that the current results show that the present optimization study is successful as it further increases the thickness.

Keywords

• Sheet Metal Thinning

References

1. [1] Application of FEA in B-Pıllar Reinforcement Forming Simulation. International Journal of Latest Engineering Research and Applications (IJLERA) ISSN: 2455-7137 Volume -02, Issue -06, June-2017, PP – 86 - 92
2. [2] https://www.engineering.com/Blogs/tabid/3207/Art icle ID/143/categoryId/11/Stamping.aspx
3. [3] Sala G. A numerical and experimental approach to optimise sheet stamping technologies: part II – aluminium alloys rubber-forming. Mater Des 2001; 22: 299 – 315
4. [4] Kim H, Sung JH, Sivakumar R, Altan T. Evaluation of stamping lubricants using the deep drawing test. Int J Mach Tools Manuf 2007; 47: 2120 – 32
5. [5] El Sherbiny M, Zein H, Abd-Rabou M, El shazly M. Thinning and residual stresses of sheet metal in the deep drawing process. Mater Des 2014; 55: 869 – 79
6. [6] Chen L, Yang JC, Zhang LW, Yuan SY. Finite element simulation and model optimization of blankholder gap and shell element type in the stamping of a washing-trough. J Mater Process Technol 2007; 182: 637 – 43
7. [7] Ghouati O, Gelin J-C, Lenoir H. Process optimization in deep drawing. Rev Eur Des Elem Finish 2000;9:129–49.
8. [8] https://www.esict.com/

9. [9] Badgujar T. Y., Wani V. P. Optimization of Stamping Process Parameters for Material Thinning With Design of Experiment Approach. IV Int. Conf. Prod. Ind. Eng. CPIE-2016, 2016,p. 1–9.
10. [10] Stamping Process Parameter Optimization with Multiple Regression Analysis Approach Materials Today: Proceedings 5 (2018) (4498 - 4507)
11. [11] Kakandikar GM, Nandedkar VM. Prediction and optimization of thinning in automotive sealing cover using Genetic Algorithm. Journal of Computational Design and Engineering Volume 3, Issue 1, January 2016, Pages 63-70.
12. [12] Colgan M, Monaghan J. Deep drawing process: Analysis and experiment. J Mater Process Technol 2003;132:35–41.
13. [13] Gunnarsson L, Schedin E. Improving the properties of exterior body panels in automobiles using variable blank holder force. J Mater, Process Technol 2001;114:168–73.
14. [14] Jawad WK, Mohamed JH. Studying the Effect of Punch Nose Radius on Deep Drawing Operation. Eng Tech 2008;26:55–73.
15. [15] Thiruvarudchelvan, S., Lewis, W. G. Deep Drawing With Blank Holder Force Approximately Proportional to the Punch Force. J Eng Ind 1990;112:278.
16. [16] WANG Y, HUANG G, LIU D, CHEN L, HAN T, PENG J, et al. Influence of blank holder type on drawability of 5182-O aluminum sheet at room temperature. Trans Nonferrous Met Soc China 2016;26:1251–8.
17. [17] Candra S, Batan IML, Berata W, Pramono AS. Analytical Study and FEM Simulation of the Maximum Varying Blank Holder Force to Prevent Cracking on Cylindrical Cup Deep Drawing. Procedia CIRP 2015;26:548–53.
18. [18] Zein H, El-Sherbiny M, Abd-Rabou M, El Shazly M. Effect of Die Design Parameters on Thinning of Sheet Metal in the Deep Drawing Process. Am J Mech Eng 2013;1:20–9.
19. [19] Sun G, Li G, Gong Z, He G, Li Q. Radial basis functional model for multi-objective sheet metal forming optimization. Eng Optim 2011;43:1351–66.
20. [20] http://www.businessdictionary.com/
21. [21] http://www.analyticsvidhya.com/blog/2015/08/comprehensive-guide-regression/
22. [22] https://reference.wolfram.com/webMathematica/tutorial/Overview.html