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Optimization of blank shape and segmented variable blank holder force trajectories in deep drawing using sequential approximate optimization

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Abstract

Blank holder force (BHF) is one of the important process parameters for successful sheet metal forming. Variable blank holder force (VBHF) that the BHF varies through the forming process is recognized as an advanced forming technology. It has also been reported that segmented VBHF (S-VBHF) is valid to a complex shape forming, but the optimal S-VBHF trajectories are rarely discussed and used. In addition to BHF, blank shape has an influence on the product quality. The blank shape minimizing the earing is still an important issue in sheet metal forming. Simultaneous optimization of both S-VBHF trajectories and blank shape is one of the crucial issues in industries. This paper proposes a method to simultaneously optimize both the segmented VBHF trajectories and the blank shape. Numerical simulation in sheet metal forming is so intensive that a sequential approximate optimization (SAO) using a radial basis function (RBF) network is adopted for the simultaneous design optimization. Based on the numerical result, the experiment using the AC servo press (H2W300, Komatsu Industry Corp.) that can conduct the optimal S-VBHF trajectories is carried out. It has been confirmed from the numerical and experimental result that the proposed approach is valid.

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Authors and Affiliations

  1. Kanazawa University, Kakuma-machi, Kanazawa, 920-1192, Japan

    Satoshi Kitayama

  2. Graduate School of Natural Science and Technology, Kanazawa University, Kakuma-machi, Kanazawa, 920-1192, Japan

    Hiroki Koyama

  3. Komatsu Industries Corp, 1-1, Ono-machi-shinmachi, Kanazawa, 920-0225, Japan

    Kiichiro Kawamoto, Takuji Miyasaka, Ken Yamamichi & Takuya Noda

Authors
  1. Satoshi Kitayama
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  2. Hiroki Koyama
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  3. Kiichiro Kawamoto
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  4. Takuji Miyasaka
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  5. Ken Yamamichi
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  6. Takuya Noda
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Correspondence to Satoshi Kitayama.

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Kitayama, S., Koyama, H., Kawamoto, K. et al. Optimization of blank shape and segmented variable blank holder force trajectories in deep drawing using sequential approximate optimization. Int J Adv Manuf Technol 91, 1809–1821 (2017). https://doi.org/10.1007/s00170-016-9877-5

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  • DOI: https://doi.org/10.1007/s00170-016-9877-5

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