A New Geometry Modification Algorithm for Blank Shape Optimization in the Deep Drawing Process
الموضوعات :Hamidreza Gharehchahi 1 , Mohammad Javad Kazemzadeh-Parsi 2 , Ahmad Afsari 3 , Mehrdad Mohammadi 4
1 - Ph.D. Student, Department of Mechanical Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
2 - Associate Professor, Department of Mechanical Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
3 - Associate Professor, Department of Mechanical Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
4 - Assistant Professor, Department of Mechanical Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
الکلمات المفتاحية: Finite Element Method, Deep drawing, Shape Optimization, Blank Optimization,
ملخص المقالة :
Deep drawing is a popular process in sheet metal forming. The goal of shape optimization of the initial blank which is considered in the present work is to find the shape of the blank in a manner in which after a deep drawing process the contour of the edges of the produced part meets a target contour. Such problems are highly nonlinear because the simulation consists of large deformation, plastic deformation, and contact. Therefore, the general approach to solving such problems is using iterative methods which are based on numerical simulation. Such an approach is also followed in the present work and a new algorithm for geometry modification of initial blank in each iteration is proposed. In the proposed algorithm, the normal distance between the final contour and target contour is used as a criterion to modify the initial blank. To evaluate the proposed algorithm a computer program is developed and to automatically execute the iterative process. One numerical example solved and the results are compared with those reported in the literature. One of the benefits of the proposed algorithm is its insensitivity to the initial guess. Therefore, to evaluate the effect of the initial guess on its performance the example was solved using different initial guesses. The results show that the proposed algorithm is robust regarding the initial guess and convergence to the optimum shape will be achieved by starting from an initial guess.
[1] Toh, C. H. and Kobayashi, S. 1985. Deformation analysis and blank design in square cup drawing. International Journal of Machine Tool Design and Research. 25(1):15-32.
[2] Chung, K., Barlat, F., Brem, J. C., Lege, D. J. and Richmond, O. 1997. Blank shape design for a planar anisotropic sheet based on ideal forming design theory and FEM analysis. International Journal of Mechanical Sciences. 39(1):105-120.
[3] Park, S. H., Yoon, J. W., Yang, D. Y. and Kim, Y.H. 1999. Optimum blank design in sheet metal forming by the deformation path iteration method. International Journal of Mechanical Sciences. 41(10):1217-1232.
[4] Son, K. and Shim, H. 2003. Optimal blank shape design using the initial velocity of boundary nodes. Journal of Material Processing Technology. 134(1):92–98.
[5] Hammami, W., Padmanabhan, R., Oliveira, M. C., BelHadjSalah, H., Alves, J. L., Menezeset, L. F. 2009. A deformation based blank design method for formed parts. International Journal of Mechanics and Materials in Design. 5(4):303-314.
[6] Fazli, A. and Arezoo, B. 2012. A comparison of numerical iteration based algorithms in blank optimization. Finite Element in Analysis and Design. 50:207-216.
[7] Itoh, T. 1989. Numerical Techniques for Microwave and Millimeter and Millimeter-Wave Passive Structures. Second Edition, New York: Wiley.
[8] Kazemzadeh-Parsi, M.J. 2014. Numerical flow simulation in gated hydraulic structures using smoothed fixed grid finite element method. Applied Mathematics and Computation. 246:447-459.
[9] Kazemzadeh-Parsi, M.J. and Daneshmand, F. 2013. Inverse geometry heat conduction analysis of functionally graded materials using smoothed fixed grid finite element method. Inverse problems in Science and Engineering. 21(2):235-250.