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Design for uncertainties of sheet metal forming process

Zhang, Wenfeng

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2007, Doctor of Philosophy, Ohio State University, Industrial and Systems Engineering.
The exclusion of inherent process variations in the current deterministic design methods for sheet metal forming can lead to very unreliable result that may cause high scrap rate, frequent rework, machine shut down and thus huge loss of profit. Extensive research has been done in exploring the deterministic effect of each factor on the part, but the impact of their variations on the fluctuation of output quality for the stamping process is seldom addressed and quantified. The inclusion of uncertainty in the design and optimization cycle should lead to better understanding of the impact of uncertainty associated with system input on the system output. This understanding can then be applied for managing such uncertainties. To date, there are very few reports on incorporating uncertainties and variations in the design of stamping processes. In this research we propose three different probabilistic design approaches. It uses sheet metal forming finite element method (FEM) simulation as the fundamental tool. When the system meta-model is not complex, the design of experiments (DOE) technique and response surface method (RSM) are integrated with FEM to build an explicit function to connect process input to process performance output. With the quantification of uncertainties of input variables, by Monte Carlo Simulation (MCS) or other reliability analysis methods, the probability that the product conforms to its specification can therefore be assessed. Through the right formulation of probabilistic optimization the robust optimal design configuration can be found. In the case where the number of process inputs is too many so that the design of experiment cannot handle and the system meta-model cannot be approximated, the alternate approach that integrates FEM, multi-objective genetic algorithm and reliability assessment is illustrated. By the proposed probabilistic design approaches, deeper understanding about the relationship between process variables uncertainties with the part qualities is achieved. Ultimately, the process output variability could be reduced, defect rates could be minimized and product quality would be improved.
Rajiv Shivpuri (Advisor)
237 p.

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Citations

  • Zhang, W. (2007). Design for uncertainties of sheet metal forming process [Doctoral dissertation, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1180473874

    APA Style (7th edition)

  • Zhang, Wenfeng. Design for uncertainties of sheet metal forming process. 2007. Ohio State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1180473874.

    MLA Style (8th edition)

  • Zhang, Wenfeng. "Design for uncertainties of sheet metal forming process." Doctoral dissertation, Ohio State University, 2007. http://rave.ohiolink.edu/etdc/view?acc_num=osu1180473874

    Chicago Manual of Style (17th edition)