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TECHNICAL PAPERS

Optimum Process Design in Sheet-Metal Forming With Finite Element Analysis

[+] Author and Article Information
Hoon Huh, Se-Ho Kim

Department of Mechanical Engineering, Korea Advanced Institute of Science and Technology, Science Town, Taejon, 305-701 Korea

J. Eng. Mater. Technol 123(4), 476-481 (Jul 24, 2000) (6 pages) doi:10.1115/1.1395579 History: Received July 24, 2000
Copyright © 2001 by ASME
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References

Badrinarayanan, S., and Zabaras, N., 1995, “Preform Design in Metal Forming,” Proceedings, NUMIFORM ’95, S. Shen and P. R. Dawson, eds., A. A. Balkema, pp. 533–538.
Fourment,  L., and Chenot,  J. L., 1996, “Optimal Design for Non-steady State Metal Forming Process-I. Shape Optimization Problem,” Int. J. Numer. Methods Eng., 39, pp. 33–50.
Maniatty,  A. M., and Chen,  M. F., 1996, “Shape Sensitivity Analysis for the Optimal Design of Metal Forming Processes,” Int. J. Numer. Methods Eng., 39, pp. 1199–1217.
Zhao,  G., and Grandhi,  R. V., 2000, “Microstructure Optimization in Design of Forming Processes,” Int. J. Mach. Tools Manuf., 40, pp. 691–711.
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Barlet, O., Batoz, J. L., Guo, Y. Q., Mercier, F., Naceur, H., and Knopf-Lenoir, C., 1998, “Optimum Design of Blank Contours using the Inverse Approach and a Mathematical Programming Technique,” Proceedings, NUMIFORM ’98, J. Huetink and F. P. T. Baaijens, eds., A. A. Balkema, pp. 178–185.
Ohata,  T., Nakamura,  Y., Katayama,  T., Nakamachi,  E., and Nakano,  K., 1996, “Development of Optimum Process Design System by Numerical Simulation,” J. Mater. Process. Technol., 60, pp. 543–548.
Lee, C. H., and Huh, H., 1998, “Estimation of Shape and Non-shape Parameters in Sheet Metal Forming Processes with Inverse Finite Element Analysis,” Proceedings, NUMIFORM’98, J. Huetink and F. P. T. Baaijens, eds., A. A. Balkema, pp. 793–799.
Hillmann, M., and Kubli, W., 1999, “Optimization of Sheet Metal Forming Processes using Simulation Programs,” Proceedings, NUMISHEET’99, J. C. Gelin and P. Picart, eds., BURS, Besancon, Vol. 1, pp. 287–292.
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Hill, R., 1950, The Mathematical Theory of Plasticity, Clarendon Press, Oxford.
Myers, R. H., and Montgomery, D. C., 1995, Response Surface Methodology: Process and Process Optimization using Design Experiments, Wiley, New York.
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Figures

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Schematic diagram of the decision procedures of process parameters
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Variation of the principal strain during optimization
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Variation of the blank holding force during optimization
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Shape of the final product of the rectangular cup drawing for the bead force calculation
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Schematic diagram of the tools, initial mesh system and the bead segments used in the rectangular cup drawing for the bead force calculation
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Target line and constraint line for the bead force calculation
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Variation of the principal strain distribution during optimization processes
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Variation of the bead force during optimization
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Die geometry of a rectangular cup drawing for the design of the die radius
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Thickness strain distribution and the weak region of the corner part with the initial design (Rdie=5 mm)
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Forming limit diagram for the design of the die radius
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Principal strain distribution before and after the optimization: (a) initial design; (b) final design
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Variation of the die radius during optimization processes

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