Multi-objective optimization of forming parameters for tube hydroforming process based on the Taguchi method |
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Authors: | Bing Li TJ Nye Don R Metzger |
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Affiliation: | (1) Department of Mechanical Engineering, McMaster University, 1280 Main Street West, Hamilton, ON, L8S 4L7, Canada |
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Abstract: | Tube hydroforming is an attractive manufacturing technology which is now widely used in many industries, especially the automobile
industry. The purpose of this study is to develop a method to analyze the effects of the forming parameters on the quality
of part formability and determine the optimal combination of the forming parameters for the process. The effects of the forming
parameters on the tube hydroforming process are studied by finite element analysis and the Taguchi method. The Taguchi method
is applied to design an orthogonal experimental array, and the virtual experiments are analyzed by the use of the finite element
method (FEM). The predicted results are then analyzed by the use of the Taguchi method from which the effect of each parameter
on the hydroformed tube is given. In this work, a free bulging tube hydroforming process is employed to find the optimal forming
parameters combination for the highest bulge ratio and the lowest thinning ratio. A multi-objective optimization approach
is proposed by simultaneously maximizing the bulge ratio and minimizing the thinning ratio. The optimization problem is solved
by using a goal attainment method. An example is given to illustrate the practicality of this approach and ease of use by
the designers and process engineers. |
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Keywords: | Finite element simulation Goal attainment method Multi-objective optimization Taguchi method Tube hydroforming |
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