Multi-Objective Six-Sigma Approach for Robust Optimization of Multi-Point Dieless Forming Process
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Online ISSN 2005-4602 Print ISSN 2234-7593
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Multi‑Objective Six‑Sigma Approach for Robust Optimization of Multi‑Point Dieless Forming Process Misganaw Abebe1 · Junseok Yoon1,2 · Beom‑Soo Kang1 Received: 13 February 2019 / Revised: 6 June 2020 / Accepted: 15 June 2020 / Published online: 3 August 2020 © Korean Society for Precision Engineering 2020
Abstract The significance of the stochastic nature of a multi-point dieless forming (MDF) process for final product accuracy has been extensively recognized. It is an under-research area in terms of effective techniques and computational tools for easy industrial applications and implementation. It is also recognized that wrinkling and dimpling are the most MDF product defects. Deterministic optimization using the finite element (FE) analysis have been used to improve the formability of the MDF process; however, not considering the noises of the system could affect the variation of the final product quality. In this study, the uncertainty parameters are considered to avoid the random variation of the final product accuracy while using the same control process parameters. In addition, to avoiding computationally expensive FE analysis, the approximation model has been used for both product defects. A six-sigma robust optimization is applied to obtain both reliable and robust MDF products. Finally a numerical simulation with one experimental result of a given target shape shows that the wrinkling and dimpling defect is controlled using the obtained optimal process parameter setup. Keywords Multi-point forming · Surrogate modeling · Wrinkling · Dimpling · Six-sigma
1 Introduction Sheet metal forming is one of the most commonly used manufacturing processes in various industries such as in aerospace, automotive, and ship construction industries. The sophisticated designs of the sheet metal formed product are more demanding these days. To manufacture those products, one of the most common sheet metal forming process is stamp forming. The conventional stamp forming is the die set forming which means different die should be designed for different target geometries. However, this is a costly method for a single or small batch product. To overcome this problem, instead of using a single die set, a discrete punch element was proposed by Nakjiman [1]. Since * Beom‑Soo Kang [email protected] Junseok Yoon [email protected] 1
Department of Aerospace Engineering, Pusan National University, Busan 46241, South Korea
Materials Deformation Department, Korea Institute of Materials Science, 797, Changwon‑daero, Seongsan‑gu, Changwon‑si, Gyeongsangnam‑do 51508, South Korea
2
then the multi-point forming process has been upgraded and used for different application [2, 3]. In addition, different researchers have been investigating the MDF process to reduce the induced defects such as wrinkling, dimpling and springback. To avoid try and error procedures for finding the proper setup of the MDF process parameters, numerical simulations have been used to evaluate the abo
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