A deformation based blank design method for formed parts

peer reviewedBlank design is an important task in sheet metal forming process optimization. The initial blank shape has direct effect on the part quality. This paper presents a deformation based blank design approach to determine the initial blank shape for a formed part. The blank design approach is integrated separately into ABAQUS, and DD3IMP, a research purpose in-house FEA code, to demonstrate its compatibility with any FEA code. The algorithm uses FE results to optimize the blank shape for a part. Deep drawing simulation of a rectangular cup geometry was carried out with an initial blank shape determined empirically. The blank shape was iteratively modified, based on the deformation history, until an optimal blank shape for the part is achieved. The optimal blank shapes predicted by the algorithm using both FEA softwares were similar. Marginal differences in the shape error indicate that the deformation history based push/pull technique can effectively determine an optimal blank shape for a part with any FEA software. For the shape error selected, both procedures estimate the optimal blank shape for the part within five iterations

Effective strategies of metamodeling and optimization of hot incremental sheet forming process of Ti6Al4Vartificial hip joint component

Despite the popularity of the Ti6Al4V alloy in many biomedical applications owing to its lightweight and mechanical properties, the applications of sheet metal-formed parts are often limited to simple shapes due to their poor strainability exhibited at room temperature. To overcome the present limits, new processes have been developed, among which the Hot Single Point Incremental Forming (HSPIF) appears as one of the most promising solutions to improve the formability as well as the shape complexity. However, there are some obstacles to its practical implementation including instability in material deformation and achievable accuracy. The present paper provides the most recent finding in the investigation of the SPIF process at a high temperature of a titanium acetabular cup by Finite Element (FE) simulations and optimization procedure. FE models were developed using ABAQUS software and the constitutive parameters, both of the material and the process were calibrated to inspect the minimum geometric errors and to avoid damage in the final component. Based on effective strategies of metamodeling, an application of four recent meta-heuristic algorithms Multi-verse MVO, Moth-flame MFO, Harris Hawk HHO, and Marine Predictor MPA is presented. The computational results prove that the evaluated techniques are very competitive in geometry optimization. Among these four optimizers, MPA is the best one that quickly estimates the pillow defect in HSPIF