Parametric Optimization of Micro Deep Drawing Process using Fem Based Taguchi Method

Abstract

In this work, a FEM based Taguchi method is used to predict the influence of forming parameters on the quality of formed part and punch force in micro deep drawing process. Three important forming parameters like punch corner radius, die corner radius and friction co- efficient are considered in this investigation. For optimization, the full factorial design of Taguchi's L27 orthogonal array is used for conducting FE simulation analysis for all the experimental runs and it is validated with set of experimental results. The FE simulation results agree with the experimental results. The signal-to-noise (S/N) ratio and the ANOVA techniques are used to calculate the significance of each parameters on the output characteristic. From the results, it is evident that the die corner radius and friction coefficient are the most influential parameters. Further a mathematical model has been developed for thickness variation in formed cup and punch force. The results of the confirmatory experiments are found to be in good agreement with the predicted results. Based on the results there is a scope to improve the micro forming process.