Determination of optimal loading profiles in hydromechanical deep drawing process using integrated adaptive finite element analysis and fuzzy control approach

Ekrem Öztürk, Mevlüt Türköz, H. Selçuk Halkacı, Muammer Koç

Research output: Contribution to journalArticle

6 Citations (Scopus)

Abstract

In this paper, an improved approach is proposed to determine the optimal profiles of two controllable process parameters (hydraulic pressure and blank holder force), which improve the forming condition and/or make better use of forming limits in hydromechanical deep drawing (HMD) process. A method based on adaptive finite element analysis coupled with fuzzy control algorithm (aFEA-FCA) was developed using LS-DYNA to determine the optimal loading profiles and thus to maximize the limiting drawing ratio (LDR). Maximum thickness reduction, maximum wrinkle height in the flange region of the sheet metal blank, and position of the nodes in the unsupported portion of the sheet metal blank between punch and die were used as criteria in the fuzzy control algorithm. Different rule-based matrices were compared by considering the maximum thinning occurred in the sheet metal blank, and thus, the most accurate matrices were determined for the control algorithm. The optimal loading profiles could be determined in a single FEA, thus reducing the computation time. The proposed approach enables determining the optimal loading profiles and also could be applied to complex parts easily. In addition, effects of initial blank diameter and coefficient of friction between the sheet-blank holder and sheet-die on the optimal loading profiles were investigated. An attainable LDR of 2.75 for AA 5754-O sheet material in hydromechanical deep drawing process was proven experimentally using the optimal loading profiles determined by adaptive FEA.

Original languageEnglish
Pages (from-to)2443-2459
Number of pages17
JournalInternational Journal of Advanced Manufacturing Technology
Volume88
Issue number9-12
DOIs
Publication statusPublished - 1 Feb 2017

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Keywords

  • AA 5754-O sheet material
  • Adaptive simulation
  • Fuzzy control
  • Hydromechanical deep drawing
  • Limiting drawing ratio
  • Optimal loading

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Software
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

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