Stretching the limits of forming processes by robust optimization: A demonstrator

J.H. Wiebenga, E.H. Atzema, E.H. Atzema, Antonius H. van den Boogaard

Research output: Chapter in Book/Report/Conference proceedingConference contributionAcademicpeer-review

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Abstract

Robust design of forming processes using numerical simulations is gaining attention throughout the industry. In this work, it is demonstrated how robust optimization can assist in further stretching the limits of metal forming processes. A deterministic and a robust optimization study are performed, considering a stretch-drawing process of a hemispherical cup product. For the robust optimization study, both the effect of material and process scatter are taken into account. For quantifying the material scatter, samples of 41 coils of a drawing quality forming steel have been collected. The stochastic material behavior is obtained by a hybrid approach, combining mechanical testing and texture analysis, and efficiently implemented in a metamodel based optimization strategy. The deterministic and robust optimization results are subsequently presented and compared, demonstrating an increased process robustness and decreased number of product rejects by application of the robust optimization approach.
Original languageEnglish
Title of host publicationNUMISHEET 2014: The 9th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes: Part A Benchmark Problems and Results and Part B General Papers
EditorsJeong Whan Yoon, Thomas B. Stoughton, Bernard Rolfe, John H. Beynon, Peter Hodgson
Place of PublicationMelbourne
PublisherAIP
Pages1061-1067
Number of pages4
DOIs
Publication statusPublished - 6 Jan 2014
Event9th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, NUMISHEET 2014 - Melbourne, Melbourne, Australia
Duration: 6 Jan 201410 Jan 2014
Conference number: 9

Publication series

Name
PublisherAIP
Volume1567
ISSN (Print)0094-243X
ISSN (Electronic)1551-7616

Conference

Conference9th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, NUMISHEET 2014
CountryAustralia
CityMelbourne
Period6/01/1410/01/14

Fingerprint

Stretching
Mechanical testing
Metal forming
Textures
Steel
Computer simulation
Industry

Keywords

  • IR-88572
  • METIS-297961

Cite this

Wiebenga, J. H., Atzema, E. H., Atzema, E. H., & van den Boogaard, A. H. (2014). Stretching the limits of forming processes by robust optimization: A demonstrator. In J. W. Yoon, T. B. Stoughton, B. Rolfe, J. H. Beynon, & P. Hodgson (Eds.), NUMISHEET 2014: The 9th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes: Part A Benchmark Problems and Results and Part B General Papers (pp. 1061-1067). Melbourne: AIP. https://doi.org/10.1063/1.4850153
Wiebenga, J.H. ; Atzema, E.H. ; Atzema, E.H. ; van den Boogaard, Antonius H. / Stretching the limits of forming processes by robust optimization: A demonstrator. NUMISHEET 2014: The 9th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes: Part A Benchmark Problems and Results and Part B General Papers. editor / Jeong Whan Yoon ; Thomas B. Stoughton ; Bernard Rolfe ; John H. Beynon ; Peter Hodgson. Melbourne : AIP, 2014. pp. 1061-1067
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Wiebenga, JH, Atzema, EH, Atzema, EH & van den Boogaard, AH 2014, Stretching the limits of forming processes by robust optimization: A demonstrator. in JW Yoon, TB Stoughton, B Rolfe, JH Beynon & P Hodgson (eds), NUMISHEET 2014: The 9th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes: Part A Benchmark Problems and Results and Part B General Papers. AIP, Melbourne, pp. 1061-1067, 9th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, NUMISHEET 2014, Melbourne, Australia, 6/01/14. https://doi.org/10.1063/1.4850153

Stretching the limits of forming processes by robust optimization: A demonstrator. / Wiebenga, J.H.; Atzema, E.H.; Atzema, E.H.; van den Boogaard, Antonius H.

NUMISHEET 2014: The 9th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes: Part A Benchmark Problems and Results and Part B General Papers. ed. / Jeong Whan Yoon; Thomas B. Stoughton; Bernard Rolfe; John H. Beynon; Peter Hodgson. Melbourne : AIP, 2014. p. 1061-1067.

Research output: Chapter in Book/Report/Conference proceedingConference contributionAcademicpeer-review

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AB - Robust design of forming processes using numerical simulations is gaining attention throughout the industry. In this work, it is demonstrated how robust optimization can assist in further stretching the limits of metal forming processes. A deterministic and a robust optimization study are performed, considering a stretch-drawing process of a hemispherical cup product. For the robust optimization study, both the effect of material and process scatter are taken into account. For quantifying the material scatter, samples of 41 coils of a drawing quality forming steel have been collected. The stochastic material behavior is obtained by a hybrid approach, combining mechanical testing and texture analysis, and efficiently implemented in a metamodel based optimization strategy. The deterministic and robust optimization results are subsequently presented and compared, demonstrating an increased process robustness and decreased number of product rejects by application of the robust optimization approach.

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Wiebenga JH, Atzema EH, Atzema EH, van den Boogaard AH. Stretching the limits of forming processes by robust optimization: A demonstrator. In Yoon JW, Stoughton TB, Rolfe B, Beynon JH, Hodgson P, editors, NUMISHEET 2014: The 9th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes: Part A Benchmark Problems and Results and Part B General Papers. Melbourne: AIP. 2014. p. 1061-1067 https://doi.org/10.1063/1.4850153