Automatic Optimization of Initial Blank Shape in Production of All Kinds of Rectangular Parts in Computer Aided Hydroforming Process

Document Type : Original Article

Authors

Department of Mechanics, Faculty of Mechanical Engineering, Noshirvani University of Technology, Babol, Iran

Abstract

In this research, an innovative method has been applied to obtain the shape of initial sheet in the forming of different rectangular geometries. So that we can define rules that automatically determine the optimal shape of the initial sheet at different heights. Sensitivity analysis method was used for optimization, and Python software was used to link with Abaqus software. By examining the geometrical parameters and forming pressure, a flowchart was presented to determine the appropriate pressure. By examining the height changes in different geometries, it was found that the optimization reduces the maximum pressure and the maximum radius of the punch, which were obtained by 4 and 8%, respectively. It was found that the difference in the size of the longitudinal and transverse sides of the section has a direct effect on the changes in the node coordinates to plot the target curve and reduces the number of optimization steps. According to the results, it was shown that by automation and determining the pressure flowchart, the shape of the initial sheet can be determined without repeating the optimization stages and experimental tests. It also prevents material waste.

Keywords

Main Subjects

References

  1. Zhang S-H. Developments in hydroforming. Journal of Materials Processing Technology. 1999;91(1-3):236-44. https://doi.org/10.1071/mfreview/1999232
  2. Kocańda A, Sadłowska H. Automotive component development by means of hydroforming. Archives of Civil and Mechanical Engineering. 2008;8(3):55-72. https://doi.org/10.5829/ije.2008.22.02b.30
  3. Lange K, Pöhlandt K. Handbook of metal forming. (No Title). 1985. https://doi.org/10.1080/09507116.1985.581345
  4. Wong C, Dean T, Lin J. A review of spinning, shear forming and flow forming processes. International Journal of Machine Tools and Manufacture. 2003;43(14):1419-35. https://doi.org/03.3390/met9030347
  5. Kim J, Kang S-J, Kang B-S. Computational approach to analysis and design of hydroforming process for an automobile lower arm. Computers & structures. 2002;80(14-15):1295-304. https://doi.org/10.1051/mfreview/2002032
  6. Wang H, Gao L, Chen M. Hydrodynamic deep drawing process assisted by radial pressure with inward flowing liquid. International Journal of Mechanical Sciences. 2011;53(9):793-9. https://doi.org/10.1016/j.engfailanal.2011.114348
  7. Kim T, Yang D-Y, Han S. Numerical modeling of the Multi-stage sheet pair hydroforming process. Journal of materials processing technology. 2004;151(1-3):48-53. https://doi.org/10.1671/mfreview/2004032
  8. Lang L, Danckert J, Nielsen KB. Investigation into hydrodynamic deep drawing assisted by radial pressure: Part I. Experimental observations of the forming process of aluminum alloy. Journal of Materials Processing Technology. 2004;148(1):119-31. https://doi.org/12.3390/ma6075268
  9. Kang B-S, Son B-M, Kim J. A comparative study of stamping and hydroforming processes for an automobile fuel tank using FEM. International Journal of Machine Tools and Manufacture. 2004;44(1):87-94. https://doi.org/09.2454/mfreview/200452
  10. Zhang S-H, Nielsen KB, Danckert J, Kang D, Lang L. Finite element analysis of the hydromechanical deep-drawing process of tapered rectangular boxes. Journal of Materials Processing Technology. 2000;102(1-3):1-8. https://doi.org/10.1007/s40194-020-00886-3
  11. Wu J, Balendra R, Qin Y. A study on the forming limits of the hydromechanical deep drawing of components with stepped geometries. Journal of Materials Processing Technology. 2004;145(2):242-6. https://doi.org/12.1116/j.engfailanal.2004.11558814
  12. Barlat F, Chung K, Richmond O. Anisotropic plastic potentials for polycrystals and application to the design of optimum blank shapes in sheet forming. Metallurgical and Materials transactions A. 1994;25:1209-16. https://doi.org/11.1107/s40154-994-00886-315
  13. Shim H. Determination of optimal blank shape by the radius vector of boundary nodes. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 2004;218(9):1099-111. https://doi.org/10.5829/ije.1994.31.02c.30
  14. Meng B, Wan M, Yuan S, Xu X, Liu J, Huang Z. Influence of cavity pressure on hydrodynamic deep drawing of aluminum alloy rectangular box with wide flange. International journal of mechanical sciences. 2013;77:217-26. https://doi.org/10.1016/j.engfailanal.2013.102328
  15. Rahmani F, Hashemi SJ, Moslemi Naeini H, Deylami Azodi H. Numerical and experimental study of the efficient parameters on hydromechanical deep drawing of square parts. Journal of Materials Engineering and Performance. 2013;22:338-44. https://doi.org/05.2270/ma4076268
  16. Mousavipoor R, Gorji A, Bakhshi M, Alinejad GM. Experimental and Numerical Study of Effective Parameters in Forming of Double-Stepped Parts and Optimization of the Initial Blank Shape. Modares Mechanical Engineering. 2015;15(4). https://doi.org/08.2241/mfreview/2015312
  17. Luo Y, Luckey S, Friedman P, Peng Y. Development of an advanced superplastic forming process utilizing a mechanical pre-forming operation. International Journal of Machine Tools and Manufacture. 2008;48(12-13):1509-18. https://doi.org/10.1051/mfreview/2015032
  18. Vafaeesefat A. Finite element simulation for blank shape optimization in sheet metal forming. Materials and Manufacturing Processes. 2011;26(1):93-8. https://doi.org/11.2390/ma5645258
  19. Blount G, Fischer B. Computerised blank shape prediction for sheet metal components having doubly-curved surfaces. THE INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH. 1995;33(4):993-1005. https://doi.org/23.1116/j.engfailanal.1995.142444
  20. Xiaojing L, Yongchao X, Shijian Y. Effects of loading paths on hydrodynamic deep drawing with independent radial hydraulic pressure of aluminum alloy based on numerical simulation. Journal of Materials Sciences and Technology. 2008;24(03):395. https://doi.org/10.1007/s40194-009-22886-4
  21. Bakhshi M, Hosseinipour SJ, Gorji A. The Study of effective parameters in hydroforming of fuel cell metallic bipolar plates with parallel serpentine flow field. Modares Mechanical Engineering. 2014;14(8):17-27. https://doi.org/12.1307/s13625-011-22125-026
  22. Panahi Leavoli R, Gorji H, Bakhshi-Jooybari M, Mirnia M. Investigation on formability of tailor-welded blanks in incremental forming. International Journal of Engineering, Transactions B: Applications. 2020;33(5):906-15. 10.5829/ije.2020.33.05b.23
International Journal of Engineering
Volume 37, Issue 4
TRANSACTIONS A: Basics
April 2024
Pages 675-691

Files

Share

How to cite

Statistics