Abstract
The purpose of this study is to produce a desired hydroformed product under the optimal pressure profile. To achieve this purpose, a new adaptive optimization approach is proposed based on fuzzy logic control (FLC) integrated with simulated annealing (SA) optimization technique and ANSYS parametric design language (APDL). An intermediate MATLAB code was developed and used to manage data transfer automatically between FLC, SA and APDL, in which there would be no need for any interaction of user/designer during the optimization process execution. This method aims to find the optimal pressure loading profile, prevent wrinkling and necking failures, reduce unsuccessful iterations, and enhance convergence precision. This method is capable of adaptively changing the process parameters in order to reach the optimized values with higher accuracy in a more reasonable time. The results show a good agreement between the proposed optimization approach and experiments. The developed optimization approach is a practical and reliable design tool for industrial production of any symmetric shell cups using hydroforming process.
Highlights
Sheet hydroforming process has found popularity due to its profitable advantages such as high product quality, enhanced formability, improved accuracy and economic feasibility in high volume production [1,2]
To obtain the optimal pressure loading profile in a shorter time with higher precision, an simulated annealing (SA) algorithm integrated with ANSYS parametric design language (APDL) code and fuzzy logic control (FLC) algorithm is adaptively developed
The maximum thinning of the hydroformed product should be checked after APDL run to check the quality
Summary
Sheet hydroforming process has found popularity due to its profitable advantages such as high product quality, enhanced formability, improved accuracy and economic feasibility in high volume production [1,2]. Development of finite element codes makes the process designers capable of modeling and producing more complicated products with better quality and shorter design time [5,6,7]. Several studies have been reported on simulation-based optimization of loading paths in sheet and tube hydroforming processes. Ray and MacDonald [9] determined the optimal loading path for tube hydroforming process using a fuzzy logic control (FLC) algorithm and finite element analysis. Choi et al [10] developed an adaptive finite element analysis with fuzzy control algorithm to determine
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