Comparison Of Simulation And Optimization Of Film Molding Based On OMD Process And 6Sigma Evaluation

OMD(Outside Mold Decoration) is a process in which a plastic film of thermoplastic properties is trimmed to the appropriate size,then softened by heating, and vacuum pressure technology is used to make the deformation on the substrate surface contours. Based on previous studies, a further theoretical analysis and research of the OMD process is done. A simulation of car dashboard OMD process film is achieved.And the optimization of the OMD process parameters(temperature, BHF, vacuum degree, etc.) is achieved by using optimization means. The best OMD process parameters is established ultimately by using the means of 6Sigma analysis. And the production of process equipment OMD accurate and efficient is paved the wayFirstly, the KDSGZ constitutive model of PC material at high temperatures is established.Based on experimental data, each parameter of the KDSGZ model is solved.Then,ABAQUS user material subroutine is written.This user material subroutine and ABAQUS is connected seamlessly. The result of car dashboard film simulation is obtained: The deformation contours of PC film in Y and X direction, The thickness contours of PC film.Then, based on the results of the analysis, the objective function(the standard deviation of 50 nodes in the dashboard shell film in which the amount of deformation in the X,Ydirection deformation and the average thickness is attained least) is designed and the variable(F, T, P1, P2, t1, t2, t3) is explicated. The Optimal Latin Hypercub method is used to sample and analysis for the results of process simulation.82 points are samplied in which 72 points are used to establish an approximate model,and the others are used to assess the accuracy of approximate model. Those data points including variables and the corresponding objective function value.In addition, the model accuracy of the RSM(second order), RBF / EBF and Kriging are good in which the approximate is obtained. Finally, The global optimization(including MIGA algorithm,ASA algorithm,PSO algorithm) for OMD process parameters that based on approximate model(Response Surface Model, Kriging Model, Neural Network Model) is achieved. The results showed that: In terms of car dashboard film process, based on EBF model,the effect of which by using ASA algorithm to optimize is remarkable.And the the mouse shell film process, based on RBF model,the effect of which by using the PSO algorithm to optimize is significant.In order to compensate for the lack of global optimization.Based on global optimization,a combination of optimization strategies for further refinement is used. In terms of car dashboard film process,based on EBF model,the effect of which by using global optimization algorithm ASA combined with NLPQL gradient optimization algorithmand to optimize is better than global optimization;And based on the second order of RSM,the effect of which by using Pointer-2 combinatorial optimization algorithm to optimize is better than global optimization too.However,the mouse shell film process,based on RBF model, the effect of which by using global optimization algorithm PSO combined with NLPQL gradient optimization algorithm to optimize is the same superior to global optimization.Finally,the reliability analysis means of 6Sigma is used to 6Sigma assessment for the optimization results of each groups.The Pareto solutions are established ultimately.Based on the second order of RSM, the Pareto solutions of which by using Pointer-2 combinatorial optimization algorithm to optimize is the best combination for car dashboard film process parameters.And based on RBF model,the Pareto solutions of which by using global optimization algorithm PSO combined with NLPQL gradient optimization algorithm to optimize is the best combination for the mouse shell film process parameters.