Parametric Optimization for Bending Process of Selective Cases Using Experimental and Simulation Techniques

Abstract

There are wide applications of bending process in automobile body and components as well as aerospace industries and there are stress variations during the process which ultimately leads to defects like tearing at edges, earring and wrinkling of the components. So this work solves the problems of defects by optimizing the stress value induced during the bending process by providing optimum parameters - punch velocity, blank thickness, type and pattern of perforation for different materials. newlineThe thesis describes the effects of parameters like material thickness, punch velocity, and stress on the bending process of sheet metal for a single component. The thesis describes experimental investigation and finite element analysis of the bending process for commercially available stainless steel, aluminum and brass materials. About 9 experiments each were conducted for all the three materials for the validation with simulation results. Experimental tests were conducted to investigate the influences of variables like punch velocity and blank thickness of the sheet metals on stress and load-displacement curve for all the specimens. Investigation of stress distributions in forming and the FEA results showed that the numerical method can predict the same stress and load as occurred in experimental newlineVII newlineKothari Kartik Dolarkumar newlinetests which were used for benchmarking and validation. More than 144 Simulations are used to present the investigation of influence of process variable on stress produced during the displacement of the punch during the bending process. Simulations are conducted to scrutinize the impact of material thickness, type of blank, blank shape, shape and pattern of perforation on stress and load-displacement curve for set of results. Weighted principal component analysis technique a multi response objective optimization method is used to derive best parameters for minimizing the induced stress value. newline