Optimization Design Of Sheet Metal Forming Based On Robustness Method

During the process of sheet metal forming, process parameters, such as frictioncoefficient, material properties and geometries, etc, have certain fluctuation aroundthe design variables. The uncertainty of the fluctuation increases the difficulty ofoptimization design, which could even affect the stability of the product quality inmass production. Therefore, we should consider the influence of uncertainty factorsand make robustness optimization design.The main work in this paper is conclued as follows:(1) This paper focuses on the research about the basic theory of robustness design,analyzes the advantages and disadvantages of three common robustness designmethods, and introduces the method of six sigma robust optimization design.(2) The finite element model of an actual automotive panel is established in thisstudy. Sensitivity analysis of the process parameters is studied, and the equivalentresistance parameters of the drawbead are screened as design variables, theformability of the rear floor crossmember has been preliminary simulation analysised.(3) A robustness optimization method is proposed for the forming parametersdesign based on the Kriging models technique, experimental design and six sigmamethods. The equivalent resistance parameters of the drawbead, which as the designvariables, are deterministic and robustness optimized. The results show that thepresented method not only improves the quality of sheet metal forming, but alsoenhances the robustness of objective function and the reliability of the designparameters.The method of six sigma robust optimization design is proposed by this paper,which can effectively improve forming process design and enhance the robustness ofthe forming quality, thus having good engineering practicability.