The Optimization of Process Parameters in hydraulic deep drawing using Taguchi and Finite Element Methods

Hydraulic deep drawing is an important manufacturing process to produce automotive parts with good strength and light weight. Many process parameters affect the product quality produced by this process. The purpose of present study is understanding of the effect of the process parameters such as maximum fluid pressure, punch velocity, punch/blank friction coefficient, die/blank friction coefficient, punch nose radius, die entrance radius, die and blank holder gap and prebulging pressure on the sheet thinning in forming of cylindrical cups using hydrodynamic deep drawing assisted by radial pressure (HDDRP). First, the process was simulated using ABAQUS commercial FE software. After validation of numerical results with experimental results, the FE model was used for performing the set of experiments designed by Taguchi’s L27 orthogonal array. The signal to noise (S/N) ratio and the analysis of variance (ANOVA) techniques were used to determine the most important parameters and also to calculate the contributions of each of the mentioned parameters on the process. The analysis results reveal that higher thickness reduction on the deformed cup can be achieved with a higher corner radius of the punch and higher die entrance radius. Also optimization results represent reduction of the thinning ratio almost 11% compared with conventional results.

کلیدواژه ها:

(S/N) ratio ، Process optimization ، Finite Element Simulation ، deep drawing