Modeling and Optimization in Manufacturing

Toward Greener Production by Integrating Computer Simulation

Catalin I. Pruncu, Jun Jiang, Jun Jiang, Catalin I. Pruncu

• Publisher: Wiley-VCH
• Year: 2021
• ISBN:
  9783527825240
• Edition: 1
• Topic: Technologie et ingénierie
• Subtopic: Science des matériaux

Discover the state-of-the-art inmultiscale modeling and optimization in manufacturing from two leading voices in the field

Modeling and Optimization in Manufacturing deliversa comprehensive approach to various manufacturing processes and shows readers how multiscale modeling and optimization processes help improve upon them.The book elaborates on the foundations and applications of computational modeling and optimization processes, as well asrecent developments in the field. It offers discussions of manufacturing processes, including forming, machining, casting, joining, coating, and additive manufacturing, and how computer simulations have influenced their development.

Examples for each category of manufacturing are provided in the text, and industrial applications are described for the reader. The distinguished authors also provide an insightfulperspective on likely future trends and developments in manufacturing modeling and optimization, including the use of large materials databases and machine learning.Readers will also benefit from the inclusion of:

• A thorough introduction tothe origins of manufacturing, the history of traditional and advanced manufacturing, and recent progress in manufacturing
• An exploration ofadvanced manufacturing and the environmental impact and significance of manufacturing
• Practical discussions ofthe economic importanceof advanced manufacturing
• An examination ofthe sustainability of advanced manufacturing, and developing and future trends in manufacturing

Perfect for materials scientists, mechanical engineers, and process engineers, Modeling and Optimization in Manufacturing will also earn a place in the libraries ofengineering scientists inindustries seeking a one-stop reference on multiscale modeling and optimization in manufacturing.

1
Modeling and Optimization in Manufacturing by Hydroforming and Stamping

Hakim Naceur¹ and Waseem Arif²

¹Université Polytechnique Hauts-de-France, CNRS, INSA Hauts-de-France, UMR 8201-LAMIH, F-59313 Valenciennes, France

²University of Gujrat, Mechanical Engineering Department, Gujrat, Pakistan

1.1 Introduction

Due to the strict environmental policies and shortage of energy, the manufacturing industries are pressurized to cut down the raw material cost and to save energy. This is particularly true in the automotive industry, where manufacturers are obliged to develop advanced techniques to reduce the pollution by reducing the fuel consumption without significant increase in the cost. Among all the manufacturing techniques, the stamping and hydroforming methods hold a top position among the cold sheet metal forming processes due to the versatility of components that can be produced and high production rates [1]. Stamping and hydroforming processes are intensively used in various industrial sectors such as transportation, car body in white (Figure 1.1), household appliances, metal packaging, etc.

The use of fluid pressure has been remarkably increased in sheet metal forming processes since it allows a superior final surface quality of the workpiece than standard deep drawing process [2–4]. In particular, sheet hydroforming process has great potential to manufacture body-in-white parts with consistently extreme level of ultimate tensile strength, reduced weight, geometrical accuracy, and minimum tolerances. It has certain advantages, e.g. more uniform thickness distribution of the final workpiece component, lower tooling cost, and versatility to produce parts with different geometries using the same setup [5].

The worldwide acknowledgment of these two sheet metal forming processes is largely due to the external pressure from the government legislators to develop lightweight products.

Stamping and hydroforming processes will be discussed in this chapter, the aim of which is to present an overview of the most recent research investigations done in the field of numerical simulation and parameters optimization of forming processes. This chapter is split into in two main topics:

Figure 1.1 Examples of parts obtained by stamping and hydroforming.

Source: Hakim Naceur.

• Numerical simulation of deep drawing and hydroforming processes: In this section, recent advances in the numerical simulation by finite element method for deep drawing and hydroforming of thin metallic sheets will be covered.
• Design and optimization of deep drawing and hydroforming parameters: The aim of this section is to cover recent research works in the field of design and numerical optimization applied to deep drawing and hydroforming processes to improve the quality of the final workpiece by calculating “ideal” process parameters.

1.2 Recent Advances in Stamping and Hydroforming Simulation

Both stamping and hydroforming processes belong to the manufacturing of complex sheet metallic parts from a flat or curved blank of small thickness (Figure 1.2a). The tube hydroforming process starts with a hollow cylindrical metal tube filled with fluid and expanded to a more complex geometry (Figure 1.2b). The material thinning can be reduced by increasing simultaneously the fluid pressure on the inside of the tube while feeding new material and axial feeding [6]. The tube can be obtained in several ways. For instance, by bending and welding of a rectangular plate; later it takes the shape of the mold by the application of internal pressure and bi-axial opposite loads on their ends which do not always have the same magnitude. In the stamping process, the blank is pressed with a certain force against the die, maintained using the blankholder, and shaped by moving the punch using a deep drawing press.

Numerical methods for deep drawing and hydroforming simulation must, as far as possible, take into...