Probabilistic design in a sheet metal stamping process under failure analysis

Thaweepat Buranathiti, Jian Cao*, Z. Cedric Xia, Wei Chen

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contribution

12 Scopus citations

Abstract

Sheet metal stamping processes have been widely implemented in many industries due to its repeatability and productivity. In general, the simulations for a sheet metal forming process involve nonlinearity, complex material behavior and tool-material interaction. Instabilities in terms of tearing and wrinkling are major concerns in many sheet metal stamping processes. In this work, a sheet metal stamping process of a mild steel for a wheelhouse used in automobile industry is studied by using an explicit nonlinear finite element code and incorporating failure analysis (tearing and wrinkling) and design under uncertainty. Margins of tearing and wrinkling are quantitatively defined via stress-based criteria for system-level design. The forming process utilizes drawbeads instead of using the blank holder force to restrain the blank. The main parameters of interest in this work are friction conditions, drawbead configurations, sheet metal properties, and numerical errors. A robust design model is created to conduct a probabilistic design, which is made possible for this complex engineering process via an efficient uncertainty propagation technique. The method called the weighted three-point-based method estimates the statistical characteristics (mean and variance) of the responses of interest (margins of failures), and provide a systematic approach in designing a sheet metal forming process under the framework of design under uncertainty.

Original languageEnglish (US)
Title of host publicationNUMISHEET 2005
Subtitle of host publicationProceedings of the 6th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes
PublisherAmerican Institute of Physics Inc.
Pages867-872
Number of pages6
ISBN (Print)0735402655, 9780735402652
DOIs
StatePublished - Aug 5 2005
EventNUMISHEET 2005: 6th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes - Detroit, MI, United States
Duration: Aug 15 2005Aug 19 2005

Publication series

NameAIP Conference Proceedings
Volume778 A
ISSN (Print)0094-243X
ISSN (Electronic)1551-7616

Other

OtherNUMISHEET 2005: 6th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes
CountryUnited States
CityDetroit, MI
Period8/15/058/19/05

ASJC Scopus subject areas

  • Physics and Astronomy(all)

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