Solving optimisation problems in metal forming using FEM: A metamodel based optimisation algorithm

During the last decades, Finite Element (FEM) simulations of metal forming processes have\ud become important tools for designing feasible production processes. In more recent years,\ud several authors recognised the potential of coupling FEM simulations to mathematical opti-\ud misation algorithms to design optimal metal forming processes instead of only feasible ones.\ud This report describes the selection, development and implementation of an optimisa-\ud tion algorithm for solving optimisation problems for metal forming processes using time\ud consuming FEM simulations. A Sequential Approximate Optimisation algorithm is pro-\ud posed, which incorporates metamodelling techniques and sequential improvement strate-\ud gies for enhancing the e±ciency of the algorithm. The algorithm has been implemented in\ud MATLABr and can be used in combination with any Finite Element code for simulating\ud metal forming processes.\ud The good applicability of the proposed optimisation algorithm within the ¯eld of metal\ud forming has been demonstrated by applying it to optimise the internal pressure and ax-\ud ial feeding load paths for manufacturing a simple hydroformed product. Resulting was\ud a constantly distributed wall thickness throughout the ¯nal product. Subsequently, the\ud algorithm was compared to other optimisation algorithms for optimising metal forming\ud by applying it to two more complicated forging examples. In both cases, the geometry of\ud the preform was optimised. For one forging application, the algorithm managed to solve\ud a folding defect. For the other application both the folding susceptibility and the energy\ud consumption required for forging the part were reduced by 10% w.r.t. the forging process\ud proposed by the forging company. The algorithm proposed in this report yielded better\ud results than the optimisation algorithms it was compared to

ANN Modelling to Optimize Manufacturing Process

Neural network (NN) model is an efficient and accurate tool for simulating manufacturing processes. Various authors adopted artificial neural networks (ANNs) to optimize multiresponse parameters in manufacturing processes. In most cases the adoption of ANN allows to predict the mechanical proprieties of processed products on the basis of given technological parameters. Therefore the implementation of ANN is hugely beneficial in industrial applications in order to save cost and material resources. In this chapter, following an introduction on the application of the ANN to the manufacturing process, it will be described an important study that has been published on international journals and that has investigated the use of the ANNs for the monitoring, controlling and optimization of the process. Experimental observations were collected in order to train the network and establish numerical relationships between process-related factors and mechanical features of the welded joints. Finally, an evaluation of time-costs parameters of the process, using the control of the ANN model, is conducted in order to identify the costs and the benefits of the prediction model adopted

Multi-objective Optimization of Tube Hydroforming Using Hybrid Global and Local Search

An investigation of non-linear multi-objective optimization is conducted in order to define a set of process parameters (i.e. load paths) for defect-free tube hydroforming. A generalized forming severity indicator that combines both the conventional forming limit diagram (FLD) and the forming limit stress diagram (FLSD) was adopted to detect excessive thinning, necking/splitting and wrinkling in the numerical simulation of formed parts. In order to rapidly explore and capture the Pareto frontier for multiple objectives, two optimization strategies were developed: normal boundary intersection (NBI) and multi-objective genetic algorithm (MOGA) based on the concept of dominated solutions . The NBI method produced a uniformly distributed set of solutions. For the MOGA method, a stochastic Kriging model was used as a surrogate model. Furthermore, the MOGA constraint-handling technique was improved, Kriging model updating was automated and a hybrid global-local search was implemented in order to rapidly explore the Pareto frontier. Both piece-wise linear and pulsating pressure paths were investigated for several case studies, including straight tube, pre-bent tube and industrial tube hydroforming. For straight tube hydroforming, the optimal load path was obtained using the NBI method and it showed a smaller corner radius compared to that predicted by the commercial program LS-OPT4.0. Moreover, the hybrid method coupling global search (MOGA) and local search (sequential quadratic programming: SQP) was applied for straight tube hydroforming, and the results showed a significant improvement in terms of the stress safety margin and reduced local thinning. For a commercial refrigerator door handle, the MOGA method was utilized to inversely analyze the loading path and the calculated path correlated well with the production path. For a hydroformed T-shaped tubular part, the amplitude and frequency of the pulsating pressure were optimized with MOGA. Thinning was reduced by 25% compared with experimental results. A multi-stage (prebent) tube hydroforming simulation was performed and it indicated that the reduction in formability due to bending can be largely compensated by end feeding the tube during hydroforming. The loading path optimized by MOGA showed that the expansion into the corner of the hydroforming die increased by 16.7% compared to the maximum expansion obtained during experimental trials

Flow stress identification of tubular materials using the progressive inverse identification method

PURPOSE : Propose a progressive inverse identification algorithm to characterize flow stress of tubular materials from the material response, independent of choosing an a priori hardening constitutive model. DESIGN /METHODOLOGY / APPROACH : In contrast to the conventional forward flow stress identification methods, the flow stress is characterized by a multi-linear curve rather than a limited number of hardening model parameters. The proposed algorithm optimizes the slopes and lengths of the curve increments simultaneously. The objective of the optimization is that the finite element simulation response of the test estimates the material response within a predefined accuracy. FINDINGS : We employ the algorithm to identify flow stress of a 304 stainless steel tube in a tube bulge test as an example to illustrate application of the algorithm. Comparing response of the finite element simulation using the obtained flow stress with the material response shows that the method can accurately determine the flow stress of the tube. PRACTICAL IMPLICATIONS : The obtained flow stress can be employed for more accurate finite element simulation of the metal forming processes as the material behaviour can be characterized in a similar state of stress as the target metal forming process. Moreover, since there is no need for a priori choosing the hardening model, there is no risk for choosing an improper hardening model, which in turn facilitates solving the inverse problem. ORIGINALITY / VALUE : The proposed algorithm is more efficient than the conventional inverse flow stress identification methods. In the latter, each attempt to select a more accurate hardening model, if it is available, result in constructing an entirely new inverse problem. However, this problem is avoided in the proposed algorithm.http://www.emeraldinsight.com/loi/echb2016Mechanical and Aeronautical Engineerin

Physical Logic Enhanced Network for Small-Sample Bi-Layer Metallic Tubes Bending Springback Prediction

Bi-layer metallic tube (BMT) plays an extremely crucial role in engineering applications, with rotary draw bending (RDB) the high-precision bending processing can be achieved, however, the product will further springback. Due to the complex structure of BMT and the high cost of dataset acquisi-tion, the existing methods based on mechanism research and machine learn-ing cannot meet the engineering requirements of springback prediction. Based on the preliminary mechanism analysis, a physical logic enhanced network (PE-NET) is proposed. The architecture includes ES-NET which equivalent the BMT to the single-layer tube, and SP-NET for the final predic-tion of springback with sufficient single-layer tube samples. Specifically, in the first stage, with the theory-driven pre-exploration and the data-driven pretraining, the ES-NET and SP-NET are constructed, respectively. In the second stage, under the physical logic, the PE-NET is assembled by ES-NET and SP-NET and then fine-tuned with the small sample BMT dataset and composite loss function. The validity and stability of the proposed method are verified by the FE simulation dataset, the small-sample dataset BMT springback angle prediction is achieved, and the method potential in inter-pretability and engineering applications are demonstrated

Material modeling for multistage tube hydroforming process simulation

The Aerospace industries of the 21st century demand the use of cutting edge materials and manufacturing technology. New manufacturing methods such as hydroforming are relatively new and are being used to produce commercial vehicles. This process allows for part consolidation and reducing the number of parts in an assembly compared to conventional methods such as stamping, press forming and welding of multiple components. Hydroforming in particular, provides an endless opportunity to achieve multiple crosssectional shapes in a single tube. A single tube can be pre-bent and subsequently hydroformed to create an entire component assembly instead of welding many smaller sheet metal sections together. The knowledge of tube hydroforming for aerospace materials is not well developed yet, thus new methods are required to predict and study the formability, and the critical forming limits for aerospace materials. In order to have a better understanding of the formability and the mechanical properties of aerospace materials, a novel online measurement approach based on free expansion test is developed using a 3D automated deformation measurement system (Aramis®) to extract the coordinates of the bulge profile during the test. These coordinates are used to calculate the circumferential and longitudinal curvatures, which are utilized to determine the effective stresses and effective strains at different stages of the tube hydroforming process. In the second step, two different methods, a weighted average method and a new hardening function are utilized to define accurately the true stress-strain curve for post-necking regime of different aerospace alloys, such as inconel 718 (IN 718), stainless steel 321 (SS 321) and titanium (Ti6Al4V). The flow curves are employed in the simulation of the dome height test, which is utilized for generating the forming limit diagrams (FLDs). Then, the effect of stress triaxiality, the stress concentration factor and the effective plastic strain on the nucleation, growth and coalescence of voids are investigated through a new user material for burst prediction during tube hydroforming. A numerical procedure for both plasticity and fracture is developed and implemented into 3D explicit commercial finite element software (LS-DYNA) through a new user material subroutine. The FLDs and predicted bursting pressure results are compared to the experimental data to validate the models. Finally, the new user material model is used to predict the bursting point of some real tube hydroforming parts such as round to square and round to V parts. Then, the predicted bursting pressure results are compared to the experimental data to validate the models in real and multistep tube hydroforming processes

AI-based design methodologies for hot form quench (HFQ®)

This thesis aims to develop advanced design methodologies that fully exploit the capabilities of the Hot Form Quench (HFQ®) stamping process in stamping complex geometric features in high-strength aluminium alloy structural components. While previous research has focused on material models for FE simulations, these simulations are not suitable for early-phase design due to their high computational cost and expertise requirements. This project has two main objectives: first, to develop design guidelines for the early-stage design phase; and second, to create a machine learning-based platform that can optimise 3D geometries under hot stamping constraints, for both early and late-stage design. With these methodologies, the aim is to facilitate the incorporation of HFQ capabilities into component geometry design, enabling the full realisation of its benefits. To achieve the objectives of this project, two main efforts were undertaken. Firstly, the analysis of aluminium alloys for stamping deep corners was simplified by identifying the effects of corner geometry and material characteristics on post-form thinning distribution. New equation sets were proposed to model trends and design maps were created to guide component design at early stages. Secondly, a platform was developed to optimise 3D geometries for stamping, using deep learning technologies to incorporate manufacturing capabilities. This platform combined two neural networks: a geometry generator based on Signed Distance Functions (SDFs), and an image-based manufacturability surrogate model. The platform used gradient-based techniques to update the inputs to the geometry generator based on the surrogate model's manufacturability information. The effectiveness of the platform was demonstrated on two geometry classes, Corners and Bulkheads, with five case studies conducted to optimise under post-stamped thinning constraints. Results showed that the platform allowed for free morphing of complex geometries, leading to significant improvements in component quality. The research outcomes represent a significant contribution to the field of technologically advanced manufacturing methods and offer promising avenues for future research. The developed methodologies provide practical solutions for designers to identify optimal component geometries, ensuring manufacturing feasibility and reducing design development time and costs. The potential applications of these methodologies extend to real-world industrial settings and can significantly contribute to the continued advancement of the manufacturing sector.Open Acces

Experimental investigation and modelling of the heating value and elemental composition of biomass through artificial intelligence

Abstract: Knowledge advancement in artificial intelligence and blockchain technologies provides new potential predictive reliability for biomass energy value chain. However, for the prediction approach against experimental methodology, the prediction accuracy is expected to be high in order to develop a high fidelity and robust software which can serve as a tool in the decision making process. The global standards related to classification methods and energetic properties of biomass are still evolving given different observation and results which have been reported in the literature. Apart from these, there is a need for a holistic understanding of the effect of particle sizes and geospatial factors on the physicochemical properties of biomass to increase the uptake of bioenergy. Therefore, this research carried out an experimental investigation of some selected bioresources and also develops high-fidelity models built on artificial intelligence capability to accurately classify the biomass feedstocks, predict the main elemental composition (Carbon, Hydrogen, and Oxygen) on dry basis and the Heating value in (MJ/kg) of biomass...Ph.D. (Mechanical Engineering Science