板料成形工艺的容差预报和稳健设计.pptVIP

Challenges from Stochastic Variations Quality fluctuation arising from stochastic variants Products with poor quality may up to 10%! The wear of the die and tool will aggravate the performance of production. Challenges from Stochastic Variations Uncertainties in sheet metal forming Uncertainness of material properties Challenges from Stochastic Variations Uncertainness of processing parameters Challenges from Stochastic Variations Effect of the uncertainties to the product quality Challenges from Stochastic Variations Controllable factors and noise factors in sheet metal forming Controllable factors factors that are easy and inexpensive to control in design and manufacturing of product include: geometric parameters, some settings for manufacturing process, etc. Noise factors factors which may affect the response but difficult to control Include: Material properties, lubrication conditions, environmental parameters and humidity, operating temperatures, degradation of tools, etc. Simulation based process optimization Process simulation and optimization Die design: from art to science FEM is widely used for simulation of sheet metal forming Optimization based on simulation technique Simulation based process optimization Limitations of simulation based optimization Too long computational time for process simulation Nonlinearity in geometry, material and contact boundary condition The simulation model involves fine mesh and complex die and product configuration Numerical inaccuracy may leads to wrong optimum results Simulation based process optimization Deterministic optimization often obtains optimized results close to the constraint boundary, which may increase the failure possibility when uncertainties exist Robustness pursuance and tolerance prediction Robust design and tolerance prediction Reliability-based optimization Robust optimization Finding the appropriate levels of controllable factors so that the final design is insensitive to variation of desi