Taguchi based GRA-PCA hybrid optimization for the forming of AL6061 alloy in automotive applications

Abstract

Current study researches the impact of material and forming factors on punch force and sheet thickness in sheet forming of Aluminum 6061 composites. The particular properties of aluminum make it the most excellent candidate to replace the heavier materials in the vehicles which act as reaction to the mass drop interest inside the car area. As of now, the high-heat treatable composites Al 6000 series alloys are applied to broad applications. The forming tests were directed depending upon L27 orthogonal array (OA) planned by taking into account about temperature, die speed, sheet thickness and type of lubricant as input for process parameters. Multi target improvement was done to decide the individual significance of every reaction through Taguchi based Grey Relational Analysis (GRA) along with Principal Component Analysis. The procedure provide the ideal parameter condition for example sheet thickness of 2mm, die and blank temperature of 300oC, die speed of 0.4 mm/s , with Boric Acid lubrication that results in 25.96% decrease in Punch power and thinning improved by 50.74%. ANOVA is valuable to make out the significance and furthermore the result of each cycle factors on response parameters. Though, considerably all the parameters play important role, the die and blank temperature affects 80.11% of the reaction parameters as that of forming factors whereas die speed turned to be the slightest significant factor. Confirmation test was performed for approving the best blend.