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Prediction and Optimization of Thinning in Automotive Sealing Cover Using Genetic Algorithm - Elsevier Enhanced Reader

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Prediction and Optimization of Thinning in Automotive Sealing Cover Using Genetic Algorithm - Elsevier Enhanced Reader

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‘Available online at www sciencedirect.com ScienceDirect Joumal of Computational Design and Engineting 3 (2016) 63-70, wo cherie comfocatelide Prediction and optimization of thinning in automotive sealing cover using Genetic Algorithm Ganesh M. Kakandikar**, Vilas M. Nandedkar” "Dryanganga Collegeof Enginering & Research, Savitri Phale Pune Univers, SNo. 38, Nar, Pune 411081, Maharashiva, Indi "Production Engineering, Shri Guru Gobind Singhit Insite of Engineering & Technology, Nanded 431606, India Recived 29 March 2015; received in revised form 8 July 2015; acepted 10 August 2015 Avilable online 28 August 2015, Abstract Deep drawing isa forming process in which blank of sheet moa is radially drawn into a forming die by the mechanical action of a punch and converted to required shape. Deep drawing involves complex material flow conditions and force distributions. Radial drawing stresses and tangential compressive stresses are induced in flange region du tothe material tention property. These compressive stresses result in wrinkling ‘phenomenon in flange region. Normally blank holder is applied for restricting wrinkles, Tensile stresses in radial direction initiate thinning inthe ‘all region of cup. The thinning results into cracking or fracture. The finite element method is widely applied workdwide to simulate the deep drawing process, For real-life simulations of deep drawing process an accurate numerical model, as well as an accurate description of material behavior and contact conditions, is necessary. The finite element method is a powerful tool to predict material thinning deformations before prototypes are made, The proposed innovative methodology combines two techniques for prediction and optimization of thinning in automotive sealing cover. Taguchi design of experiments and analysis of variance has been applied to analyze the influencing process parameters on Thinning. Mathematical relations have been developed to cotrelate input process parameters and Thinning, Optimization problem has been ‘oemutated for thinning and Genetic Algorithm has been applied for optimization, Experimental validation of results proves the applicability of ‘newly proposed approach, The optimized component when manufactured is observed to be safe, no thinning or fracture is observed. {© 2015 Society of CADICAM Engineers. Production and hosting by Elsevier. AU rights reserved. This is an open access article under the CC BY-NC-ND license (htip:/ereativecommons ore/icensevby-ne nd), Keywords: Thing; Prediction; DOE; Regression 1. Metal forming - Introduction Sheet metal forming is a significant manufacturing process for producing a large variety of automotive parts, aerospace components as well as consumer products (kitchen sinks, cans, boxes, etc.). These are broadly classified as forming/drawing/ stamping and deep drawing operations, which include a wide spectrum of operations and flow conditions, Deep drawing is a compression-tension forming process |1. With the greatest range of applications involving rigid tooling, draw punches, a blank holder and a female die. In this process the blank is *Conesponding author. Te: +91 20 67206117; fx: +91 98 6068 1885 Email addresses: Kkandikse@ gmail.com (GM. Kakandika), vias minded gmail om (V.M, Nanded) aa dong. 16 oe 2015 08.001 generally constrained over the draw punch into the die to give required shape of cavity. The sheet material is subject to a large plastic deformation combined with a complex flow of material, Design in sheet ‘metal forming, even after many years of practice, still remains ‘more an art than science. This is due to the large number of parameters involved and their interdependence, These are ‘material properties, machine parameters such as tool and die geometry, work piece geometry and working conditions. Research and development in sheet metal forming processes requires lengthy and expensive prototype testing and experi- ‘mentation in arriving at a competitive product, In deep drawing of a cup the metal is subjected to three different regions of deformations. Fig. | represents the deforma- tion and stresses developed in a pie-shaped section, The metal at the center of the blank under the head of the punch is wrapped 2288-4 300/6 2015 Society of CADICAM Enginosrs.Prodoction and hosting by Ekevit. Al sgh reserved. Tis is open acces tile under he CC BY-NC ND license (hap/eestivecommons rplicensexby ne nd. ot GM, Kakandtar, Vs Fig. 1. Stat of sess in doep deawing around the profile of the punch. ‘The metal in this region is, subjected to biaxial stress duc to the action of the punch. The metal is bent over the Punch Radius which causes friction, At the center of cup there ino strain and no friction, Metal in the outer Portion ofthe blank is drawn radially inward towards the throat of| the dic [2]. However, as the metal passes over the die radius, itis first bent and straightened, while at the same time being under tensile stresses, this eauses considerable friction. As itis drawn in, the outer circumference must continuously decrease from that of| the original blank, to that of the finished cup. This means that it is subjected to a compressive strain in the circumferential or hoop dirzction and a tensile stain in the radial direction, ‘Asa result of these two principal strains there is a continual increase in the thickness as the metal moves inward in the flange region. This plastic bending under tension results in considerable thinning; this modifies the thickening due to the circumferential shrinking. The proposed innovative methodol ‘ogy combines two fechniques for optimization of thinning in ‘automotive sealing cover. Taguchi design of experiments and, analysis of variance is used to analyze the influencing process Parameters on thinning, Mathematical relations have been developed to relate input process parameters and thickness reduction. Optimization problem has been formulated and Genetic Algorithm is applied for optimization, There are a lot of Evolutionary and Bio Inspired optimization algorithms available nowadays, such as Particle Swarm Optimization, Ant Colony Optimization, etc. Genetic Algorithm has its own advantages and capabilities which have been discussed in the following sections. 2. Major influential parameters Four major process variables have been studied in Numer ical Investigations for Sealing Cover to understand the effects ‘of these parameters and their interaction on thinning. These are blank holder force, lubrication condition i. coefficient of frietion, die profile radius and punch nose radius. 21. Lubrication Lubrication is normally expressed in terms of coefficient of fiction. In deep drawing all areas where sheet and tool slide Nandedtar /Joumal of Computational Design and Engineering 3 (2016) 63-70 are relative to each other and plastic deformation occurs with complex state of friction [3]. The sheet is stretched over the stamp; inthis ease the friction between the stamp and the sheet toa large extent determines the deformation. In some positions where the sheet slides over the edge of the dic with a simultaneous shearing of the sheet material, the friction between die and sheet influences the coefficient which is assumed between 0.05 and 0.15. Schey [4] distinguishes a total ‘of six contact and friction regions in deep drawing. Too low a {fiction involves a poor control of the sheet flow, because sheet will flow easily with a risk of wrinkling. While 100 high a friction leads 10 a risk of crack formation, because the slow ‘movement of sheet can result into tearing and eracl 2.2. Blank holding force ‘The blank holder force is applied to control the flow of material in the die, Blank holder force has_ significant contribution on the product quality. Appropriate blank holder force evolved through a process results in controlling. the thickness variations in a deep drawn part and thus the quality Of the part. An optimal blank holder force eliminates wrinkling, as well as tearing, the two major phenomena that cause failure in formed parts. During numerical investigations, a constant blank holder force is applied during a forming process to minimize mechanisms in the forming tools 2.3. Punch nose radius ‘The draw punch applies the required force onto the sheet ‘metal blank in order to cause the material 10 flow into the die cavity. The critical features of the draw punch include the punch face and Punch Nose Radius, Punch Nose Radius cannot be too small as it will try to pierce or cut the blank rather than force the material to bend around the radius [5]. ‘The minimum punch-nose radius depends on material type and thickness. It is equally important to understand that, as the punch-nose radius is increased the blank will tend to stretch on the punch face rather than draw-in the blank edge. 24. Die profile radius ‘The die profile radius and die-face surface are probably the ‘most influential features in a draw tool that uses a flat blank holder (6]. If the draw radius is too small the part may split as the material deforms. This is due to the high restraining forces caused by bending and unbending of the sheet metal over a tight radius. Drawing over a tight radius also produces a tremendous amount of heat, This can lead (© microscopic welding of the sheet metal (0 the tools, known as galling, On the other hand, an excessive die radius causes the blank to \wrinkle in the unsupported region between the punch face and the die face. It is apparent that there must be some range of die radii to select from that will work; not to0 small and not too big. GM, Kahana, VM. Nandedtar / Journal of Compusaional Design and Engineering 3 (2016) 63-70 6 3. Thinning Deep drawing is a high order non-linear problem in ‘numerical modeling [7]. The thinning refers to reduction in thickness than the original thickness of blank at various cross sections of the components. The conventional deep drawing process is limited (© a certain Limit Drawing Ratio (LDR), beyond which localized wall thinning and rupture occur. One ‘way to increase the LDR is to uy to capture the onset of necking and to adjust process parameters in order to delay or avoid necking [8]. The limiting drawing ratio decreases as sheet thickness decreases and it decreases rapidly below 0.04 mm thickness [9]. Prediction of the forming results, determination of the thickness distribution and the thinning ff the sheet metal blank will decrease the production cost through saving material and production time [10]. In this research thinning is measured from the simulation results of thickness at various eross sections, where it has reduced than that of original, and average reduction in thickness is ealcu- lated. Average reduction in thickness is used for analysis of 4. Sealing cover — automotive component under investigations Sealing cover is manufactured by Vishwadeep Enterprises, Chikbali, Pune, for Dali and Samir Engineering Private Limited. It is fitted to two wheeler petrol tank. The configura- tion of sealing cover is very simple, but quite different from ‘ypical cup. ICis having large diameter to height ratio and there is no flange (Figs. 2 and 3). ‘The base has a curvature with 150mm radius. The cup diameter is of 58.6 mm and total height is 09 mm. The base comer radius is of 2mm, The material is SPCC and it is. a «drawn component, where diameter to depth ratio is very high. 5. Proposed methodology A. Numerical experimentation is carried out with Taguchi Design of Experiments involving input parameters. and performance measure as thickness reduction, B. Analysis of variance is carried out to predict the effect of input parameters on thickness distribution. Sensitive para meters are identified. C. Regression is applied for mathematical modeling. This the major contribution of authors. Fi, 2, Scaling cover Fig 3, Sealing cover ~ edge displacement, D, Optimization problem is formulated and Genetic Algorithm is applied. The Process variables have been selected with ‘extensive literature survey and the lower and upper bounds have been decided with industry manufacturing them. ‘Optimum combination of parameters is applied in numer- simulation after optimization using Genetic Algorithm, So itis the most effective combination of parameters E. The results of optimization are validated with experimental resis. 6. ‘Taguchi experiments ~ orthogonal arrays ‘The Taguchi design of experiments involves reducing the variation in a process through robust design of experiments ‘The Taguchi method was developed by Dr. Genichi Taguchi of Japan. Taguchi developed a method for designing experiments to investigate how input parameters affect the mean and variance of a process performance characteristic that dofines hhow well the process is functioning, The experimental design proposed by ‘Taguchi involves using orthogonal arrays 10 organize the parameters affecting the process and the levels At which they should be varied. Instead of having to test all possible combinations like the factorial design, the Taguchi ‘method tests pairs of combinations {11 ‘This allows for the collection of the necessary data to determine which factors most affect product quality with a ‘minimum amount of experimentation, thus saving time and resources. During present investigations for sealing cover, four parameters are selected as blank holder force [BHF], lubrication-coefficient of friction (punch nose radius [Ry] and die profile radius [Rp]. Three levels of each parameter are selected. Taguchi suggests L9 orthogonal array for. four parameters and three levels. The design along with three levels of parameters is presented in Table | {12}. 7. Numerical investigations Numerical simulations of sheet metal forming processes, based on finite element method (FEM), represent a powerful tool for prediction of forming processes and are used worldwide [13], Numerical simulations have been carried out for all nine designed experiments using Forming Suite. Forming Suite is a popular solver for metal forming from Forming Incorporations, 66 GM, Kakandtar, Vs Table 1 9 Onhogonal aray for sealing cove. Nandedtar /Joumal of Computational Design and Engineering 3 (2016) 63-70 Lower Mile Higher BHE ODkN O3KN OFKN) 1 05 010 ous RD. 13mm) 20mm 25mm RP 600mm 70mm somm Blank holder foree Cocfcient of trcton Die profile radius Pune nose radius r @ ‘005 1s 60 2 o 10) 20 10 3 o as 25 80 4 0 008 20 80 5 03 10 5 60 6 03 ous 15 10 7 ot 008 2s 10 5 ot 010) 1s 80 9 oF as 20 60 ‘Canada, One of the major reasons of rejection in deep drawn parts is due to thinning and then fracture or cracks. Therefore, the thickness distribution is measured in numerical experiments as response. Following figures elaborate the state of thickness in all experiments designed. Original thickness of sealing cover is, (0.8 mm, whereas maximum thickness is observed to be 0.847 in ‘experiments one and four. The minimum thickness observed is (0.767 mm in experiment nine, All the experiments show more ‘or less thinning behavior. The various colored bands show various thickness ranges. The average thickness in thinning region is measured as shown in Table 2 (Fig. 4). 8. Analysis of variance ‘To establish the relationships between investigated process Parameters and thinning effect, analysis of variance is carried ‘out aller numerical experimentation. Signal to noise ratio measures quality with emphasis on variation of process [14] ‘The SIN ratios were calculated for minimizing the thinning, criterion selected is minimum the better. The formula applied si 0 log (Sum of squae off Original Thickness-Reduced Thickness] wo ‘Table 2 represents the thickness distribution for all experi- ments in simulations of Sealing Cover. ‘The minimum thickness observed is 0.785 mm in second experiment, The mean S/N ratios were calculated for all parameters blank holder force, coefficient of riction, die profile radius and punch nose radius at all three levels low, ‘medium and high as shown in Table 3. The range is defined as the difference between maximum and minimum value of SiN ratio for particular parameter, Higher the range higher is the rank indicating that the parameter is more sensitive and influential on response. The results of orthogonal array indicate that friction has major influence on thinning. Punch nose radius has second rank; blank holder force has third rank and die profile radius has least influence. Table 2 SV atos for seating over Expt. Decreased Avorige “Thickness sv to. thickness (mm) thickness mm) dfeenee (MM) ratios 1078 0793 0797 0791 ‘0.00% 4128 2 0793 0789 0.773 0785 3687 3780 0.790 0.798 0788 3st 40792 0797 — 0794 4319 5S U7k2 0790 0795 0789 307 6 0.790 0780 0786 0.786 339 70792 0796 0787 0.791 4138 8 079407 — 072 4198 90.795 0790 0785 0.790 0.00 9, Problem formulation Deep drawing process shows non-linear behavior, But the component under study is not deep drawn; the depth as compared {0 diameter ix very less, so linear relationship has been applied. Eq, 2 below is the relation between four input parameters and reduction in thickness as performance measure, Which is established using regression analysis. Minitab is used for linear regression [15]. ‘THINNING = 0.795 — 0.000133 BHF 0.243 j1— 0.00033 RD—0.00217 RP (2) ‘An optimization problem has been formulated with the following constraints. Minimize F, F = THINNING = 0.795— 0.000133 BHF +0.243y1—0,00033 RD 0.00217 R Subjected to 1.2 < pf < 22 8) 3Rp

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