Optimisation of springback in bending processes using FEM simulation and response surface method

The aim of this work includes the springback optimisation of bending processes using the concept of experimental design and response surface methodology (RSM). The optimisation method includes two phases. The first involves the objective function prediction using design of experiments and response surface method, while the second is an optimisation process using a FORTRAN gradient algorithm. Springback of sheet parts during bending processes is simulated using finite element model (FEM) including damage evolution effects within the sheet. The numerical simulation of the damage evolution has been modelled by means of continuum damage approach. The Lemaitre damage model, taking into account the influence of triaxiality, has been implemented into ABAQUS/Standard code in order to predict the external fibres rupture evolution during the process and the material characteristics changes after bending. The simulation included die corner radius and punch-die clearance as the main variables.     

Optimal design of a variable stiffness joint in a robot manipulator using the response surface method

The response surface method combined with the design of experiment-based design optimization of a variable stiffness joint (VSJ) is presented in this article. A VSJ used in a manipulator of a robot arm to support 1 kg payload at the end is designed by considering the minimization of the total weight as the objective function. Owing to the requirement of large rotational stiffness of the VSJ, over 10 N · m, ring-type permanent magnets are adopted. First, a model composed of two permanent magnets was initially manufactured and tested for comparison with the analysis results. Then, a three-ring-type permanent magnet-based model is suggested and optimized to increase the torque of VSJ. The finite element method is used as a magnetic field analysis method to substitute for the expensive experimental process. Optimization results decrease the weight from 0.899 kg to 0.538 kg, still satisfying the requirement for the rotational stiffness. This paper was recommended for publication in revised form by Associate Editor Tae Hee Lee Jeonghoon Yoo received his B.S. and M.S. degrees in Mechanical Design and Production Engineering from Seoul National University, in 1989 and 1991, respectively. He then received his Ph.D. degrees from the University of Michigan, Ann Arbor, in 1999. Dr. Yoo is currently a Professor at the School of Mechanical Engineering at Yonsei University in Seoul, Korea. Dr. Yoo’s research interests include analysis and design of electromagnetic field systems. Myung Wook Hyun received his B.S. and M.S. degrees in Mechanical Engineering from Yonsei University, Korea, in 1995 and 1997, respectively. While studying for his M.S. degree, Mr. Hyun also studied variable stiffness unit design. He is now working at Samsung Electronics, Co. Ltd.. Jun Ho Choi received his B.S. and M.S. degrees in Mechanical Design from Hanyang University, Korea and his Ph.D. degree from the University of Michigan, Ann Arbor. He is currently a senior research scientist in the Korea Institute of Science and Technology. His research interests include nonlinear control, manipulator control, and safe-joint design. Sungchul Kang received his B.S., M.S., and Ph.D. degrees in Mechanical Design and Production Engineering from Seoul National University, Korea, in 1989, 1991, and 1998 respectively. Dr. Kang is currently a Principal Research Scientist in the Center for Cognitive Robotics Research, Korea Institute of Science and Technology, in Seoul, Korea. Dr. Kang’s research interests include mobility and manipulation of field and service robots and haptics. Seung-Jong Kim received his B.S. degree in Mechanical Engineering from Seoul University, Korea, in 1989, and his M.S. and Ph.D. degrees from KAIST in 1991 and 1998, respectively. Dr. Kim is currently a Principal Research Scientist at the Korea Institute of Science and Technology in Seoul, Korea. Dr. Kim’s research interests include the design, control, and dynamic analysis of mechatronic systems.     

Optimization of drawbead design in sheet forming using one step finite element method coupled with response surface methodology

In a sheet forming process, drawbead plays an important role on the control of the material flow. In this paper, a numerical procedure for the design of forming processes is described. It is based on the coupling of an optimization technique and the simplified one step finite element method (also called inverse approach). The optimization technique allows adjustment of the process parameters so that specified criteria are fulfilled. Response surface methodology (RSM) is a global approximation method, which is ideally suited for solving highly nonlinear optimization problems. The finite element method, in addition to predicting the response of the process to certain parameters, allows assessment of the effect of a variation in these parameters on this response. The authors utilize the one step method at the preliminary design stage to supply stress or strain information for the following optimization using RSM. The procedure for this optimization process is fully described. The front fender for Numisheet 2002 is presented and the real defect free workpiece is produced to demonstrate the usefulness of the proposed optimization procedure. A comparison between the two forming limit curves (FLC) before and after optimization and results obtained using the precise incremental commercial software DYNAFORM based on the explicit dynamic approach verify that the optimization design method of drawbead could be successfully applied in designing actual tools of auto body cover panels.     

Optimum design of roll forming process of slide rail using design of experiments

In the design of the roll forming process, design errors can be determined in advance by using an FE simulation tool such as SHAPE-RF. In the case of a product such as a slide rail having a complicated shape and requiring high-precision forming, a standard is necessary for quantitatively evaluating the quality of the formed shape. In the analysis of the roll forming process of a slide rail, the pass having the largest deformation is designated as the target pass and the positions and shapes of the rolls are set as design variables. A minimum number of simulations was performed by using the table of orthogonal arrays. A cost function was obtained from the results by using the design of experiments such as the response surface method and it was minimized for satisfying the design constraints. By improving the design of the target pass, the shape of the final product approaches that intended by the designer.     

Assessment of sculptured surface milling strategies using design of experiments

Product manufacturing on CNC milling machine tools involves a number of machining parameters and tool geometries. In the case of sculptured or free-form surfaces the number of these parameters can be significantly large and vary according to surface complexity. Minimising the number of parameters is carried out through statistical elimination. Design of experiments (DoE) along with the respective statistical analysis of variance (ANOVA) constitutes a low-cost useful tool in determining sub-optimum values for all parameters involved in each milling strategy as well as the most significant of those parameters. DoE was implemented for a particular sculptured surface assessing a variety of roughing and finishing strategies of a CAM simulation software.     

Validation of a method using Taguchi,response surface,neural network,and genetic algorithm

Piston is one of the important parts for aircraft engine, and the quality of piston affects the efficiency and safety of the engine. This study applies Taguchi method, response surface methodology (RSM), and back-propagation neural networks (BPNN) combining with genetic algorithm (GA) on the quality improvement of piston manufacturing processes to enhance the process yield. The Taguchi parameter design concerns three nominal-the-best specifications, including ring groove diameter specification, inner groove diameter specification, and inner diameter of pistons. Together with five control factors consisting of (1) type of carbon steel, (2) type of cutting fluid, (3) cutting depth, (4) spindle speed, and (5) chuck pressure, the L₂₇(3¹³) orthogonal array was selected for this experiment. Three models: (1) Taguchi model, (2) Taguchi_RSM model, and (3) Taguchi_BPNN_GA model were constructed to find the parameter combinations of five control factors for each model. Confirmation experiments were done for each model and the performances of three models were also compared to indict the enhancement of manufacturing quality of piston.     

Optimal design of high temperature vacuum furnace using response surface method

A new method using the response surface method and optimization technique has been developed instead of the original method based on trial and error. In order to construct a response surface, thermal analysis was performed under the condition of using the calculated thermal conductivity of the insulator in a previous study. In order to set up the response surface, the D-Optimal method was used in the process of selecting experimental points. Using a weighting factor, an optimization study was carried out under the condition of satisfying user requirements. Finally, the merits and drawbacks of the new method were described by comparing with the optimal design method based on the thermal analysis database which was developed in a previous study. The optimal results show that the developed method can be used to design an energy efficient, low manufacturing cost, high temperature vacuum furnace with avoiding unnecessary iterative manufacturing, and anticipating the performance before manufacturing. This paper was recommended for publication in revised form by Associate Editor Ohchae Kwon     

Efficient warpage optimization of thin shell plastic parts using response surface methodology and genetic algorithm

During the production of thin shell plastic parts by injection molding, warpage depending on the process conditions is often encountered. In this study, efficient minimization of warpage on thin shell plastic parts by integrating finite element (FE) analysis, statistical design of experiment method, response surface methodology (RSM), and genetic algorithm (GA) is investigated. A bus ceiling lamp base is considered as a thin shell plastic part example. To achieve the minimum warpage, optimum process condition parameters are determined. Mold temperature, melt temperature, packing pressure, packing time, and cooling time are considered as process condition parameters. FE analyses are conducted for a combination of process parameters organized using statistical three-level full factorial experimental design. The most important process parameters influencing warpage are determined using FE analysis results based on analysis of variance (ANOVA) method. A predictive response surface model for warpage data is created using RSM. The response surface (RS) model is interfaced with an effective GA to find the optimum process parameter values.     

Principles of new method of optimisation, design and modelling of pipeline A/D converters

The paper presents the foundations of a new approach to design, optimisation and modelling of a new class of pipeline analogue-to-digital converters (PADC). The approach employs the results of analytical and applied research on the concurrent optimisation of the analogue and digital parts of adaptive estimation systems. Application of the approach allows to modify the known architecture and principles of conversion used in conventional PADC in the way significantly improving quality of conversion. Particularities of functioning of new PADC were studied in advanced simulation experiments, which confirmed the results of analytical investigations. Special attention was paid to comparison of the performance of new and known PADC and assessment of potentially achievable benefits.     

基于响应面法的桥梁主桁架结构优化设计

对复杂结构进行优化设计和可靠性设计时,利用传统的设计方法可能会遇到计算量太大的困难,应用响应面法是有效地解决该问题的途径之一.文中将响应面法和有限元技术相结合,建立了桥梁主桁架的挠度、弯曲应力与结构尺寸的函数表达式,继而对主桁架进行了结构优化设计,最后对优化结果进行了有限元分析和验证.设计计算结果表明,对于桁架结构设计这类问题,响应面优化设计具有很好的应用价值.     

Use of design of experiments and Monte Carlo method for instruments optimal design

A common issue in the design of measurement instruments is the comparison between different solutions in terms of components of the measurement chain, data processing or even measurement principles; the predicted instrumental uncertainty is the driving parameter for such a comparison. While in many situations the linearization of the measuring model allows using the standard ISO GUM procedure, in complex cases it might be necessary to proceed with Monte Carlo simulations as per ISO GUM supplement 1. This paper describes a method that combines the factorial design of experiments (DOE) and the ISO GUM supplement 1 uncertainty evaluation method to guide the instrument designer in the instrument configuration optimization. The proposed approach allows estimating, in the design phase, the overall instrumental uncertainty for different configurations, the instrument sensitivity to the accuracy in the measurements of its inputs and the effects on systematic and random measurement errors deriving from the choice of all instrumental variables. The use of data populations selected with the DOE criteria allows recovering valuable parameters equivalent to the sensitivity factors of the GUM linearized approach. The data analysis allows separating the critical factors that must be accurately controlled from those only weakly affecting the measurement uncertainty. The method has been applied to a case study where the metrological performances of a system devoted to the measurement of the acoustic radiation emitted by a vibrating panel in a reverberant enclosure had to be assessed.     

Analysis of shrinkage and warpage in an injection-molded part with a thin shell feature using the response surface methodology

This paper presents a systematic methodology to analyze the shrinkage and warpage in an injection-molded part with a thin shell feature during the injection molding process. The systematic experimental design based on the response surface methodology (RSM) is applied to identify the effects of machining parameters on the performance of shrinkage and warpage. The experiment plan adopts the centered central composite design (CCD). The quadratic model of RSM associated sequential approximation optimization (SAO) method is used to find the optimum value of machining parameters. One real case study in the injection molding process of polycarbonate/acrylonitrile butadiene styrene (PC/ABS) cell phone shell has been performed to verify the proposed optimum procedure. The mold temperature (M _T), packing time (P _t), packing pressure (P _P) and cooling time (C _t) in the packing stage are considered as machining parameters. The results of analysis of variance (ANOVA) and conducting confirmation experiments demonstrate that the quadratic models of the shrinkage and warpage are fairly well fitted with the experimental values. The individual influences of all machining parameters on the shrinkage and warpage have been analyzed and predicted by the obtained mathematical models. For the manufacture of PC/ABS cell phone shell, the values of shrinkage and warpage present the reduction of 37.8 and 53.9%, respectively, using this optimal procedure.     

Numerical simulation of free flow through side orifice in a circular open-channel using response surface method

A side orifice is an important type of hydraulic structure which is used widely in irrigation and waste management systems to divert desired discharges from a main channel or to distribute the flow within the basins. Circular pipes flowing partially full are often used in these systems, but existing predictive relations developed for rectangular channels result in significant error. In the present study, the flow through a side orifice in a circular open-channel is numerically simulated and validated to test the effect of different parameters on the discharge coefficient and propose an appropriate predictive equation. To minimize the number of required simulations and validations, a Response Surface Method-Central Composite Design (RSM-CCD) is employed. Results showed that the discharge coefficient is inversely related to the Froude number (Fr) and the ratio of the side orifice length to the approaching flow water depth. However, any increase in either the ratio of the orifice length to the main channel diameter or the ratio of the lower crest level to the orifice length will increase the discharge coefficient. A new equation is presented to determine the discharge coefficient of side orifice in a circular open-channel using RSM-CCD. The sensitivity analysis showed that all linear terms must considered in the equation but that the interaction terms can be dropped. The maximum error of the equation to predict the training and validation data are 1% and 2% respectively.     

基于人体表面三维数据的医用支具逆向设计方法

为促进医用支具的个性化快速定制,对人体造型特征进行了分析。结合逆向工程、模具设计、3D打印等技术,论述了基于人体表面三维数据的医用支具逆向设计方法。以颈部支具设计为例,验证了该设计方法的合理性和可行性。     

基于三维CAD的智能化工装设计与管理系统研究

工装设计与管理是现代企业加工中的一个重要环节。这里分析了工装设计的特点;设计了基于三维CAD系统的智能化工装设计与管理系统,阐述了系统的结构、功能工作流程以及与其它系统的信息集成,并以UG的三维软件为基础实现了原型系统。     

System identification of a composite plate using hybrid response surface methodology and particle swarm optimization in time domain

Material properties of composites are identified using a novel hybrid RSM–PSO method in this paper. Different response surface methodology (RSM) methods and particle swarm optimization (PSO) methods are studied initially on a 4 degrees-of-freedom (4DOF) dynamic system on their performance in terms of speed and accuracy. The best combination is used as a hybrid RSM–PSO method to evaluate the performance on system identification of an orthotropic plate along with a 4DOF dynamic system and an isotropic plate. The novelty of the present paper is to identify the composite plate material properties using RSM methods based on time domain signals, which is not hitherto reported in the literature. Also, whereas previous papers have used full factorial design for system identification, here CCDI is used. The input factors (design variables) are the system parameters which are to be identified and the response (objective function) is error sum-of-square of acceleration response with respect to new test system. The performance of the proposed method is also evaluated with the addition of 5% Gaussian noise to simulate the experimental errors. The system parameters of the orthotropic plate were identified with 0% and 0.25% average prediction error with zero and 5% addition of noise respectively by the proposed hybrid RSM–PSO method. It is also showed a much better performance and robustness to noise addition when compared to the other RSM methods in the literature.     

基于有限元法催化剂颗粒撞击壁面的数值模拟

为解决催化裂化装置中的许多构件因为催化剂颗粒长期不断冲击而导致失效等的问题,将有限元法应用到其模拟仿真中,分析了单颗催化剂颗粒参数(角度、速度、材料)对不同壁面材料的撞击而造成壁面磨损的影响,建立了催化剂颗粒撞击壁面的数值分析模型,研究了催化剂颗粒以不同的速度、撞击角度,以及不同的催化剂颗粒的材料撞击不同材料的壁面对壁面造成的影响,并分析了催化剂颗粒变形对壁面磨损的影响,根据计算的结果,对催化剂颗粒参数进行了优化控制,提出了减少催化剂颗粒变形和构件磨损的技术措施.研究结果表明,该方法能够使催化裂化装置长期安全稳定地运行.     

基于RSM-AGA的永磁驱动器周向开槽的参数优化设计

针对永磁驱动器工作效率较差的问题,提出一种导体盘上周向开梯形槽的永磁驱动器,采用有限元仿真确定了永磁驱动器导体盘的开槽个数,联合中心复合设计和响应面法建立了响应变量与设计变量之间的响应面模型。基于该模型,选择适当的约束条件,以传动转矩最大和涡流损耗最小为优化目标,利用自适应遗传算法对永磁驱动器的开槽结构参数进行优化。优化结果使开槽结构永磁驱动器的传动转矩与原始设计相比增加了24.439 8 N·m,涡流损耗减小了36.44 W,重量减小了3.748 1 kg。有限元仿真实验验证了开槽结构可以优化涡流路径,减少杂散电流,进一步提高永磁驱动器的传动转矩。