An optimization methodology for preform design in forming processes via FEM simulation

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An optimization methodology for preform design in forming processes via FEM simulation


Author: Hu, Difeng
Title: An optimization methodology for preform design in forming processes via FEM simulation
Degree: M.Sc.
Year: 2008
Subject: Hong Kong Polytechnic University -- Dissertations.
Engineering design -- Mathematical models.
Finite element method.
Computer-aided engineering.
Department: Dept. of Mechanical Engineering
Pages: ix, 126 leaves : ill. (some col.) ; 30 cm.
Language: English
InnoPac Record:
Abstract: Successful engineering design is dependent on the appropriate usage of available resources. In the past product design, optimization is generally established by a trial and error which is not only cumbersome, time-consuming but also not cost effective. With the advent of FEM and commercial CAE software system, the time and cost for product design and development are significantly decreased. However, for complicated products with many design parameters, the design and development lead-time is still quite long, shortening product time-to-market is critical. Taguchi technique which can indicate the design trend by using a limited number of trials is used to tackle the full-factorial problem. However traditional Taguchi method could just deal with mono-criterion problems. In this research, a method to simplify the parameter is introduced firstly by using this method thousands of parameters can be decreased into several ones. In this way, design parameter configurations can be considerably reduced and the number of trials could be cut down into a desirable range. To reach this goal an optimization methodology is proposed to obtain the optimal design scenario via implementing the simulation by coalescing Computer-Aided Design (CAD), Finite Element Analysis (FEA), Material Science Theory, Design theory, Optimization Process Control, and Taguchi technique to achieve a robust design of preform. Every criterion indicates its own property to the final product. It is difficult to directly integrate all of criteria taken into consideration. Using the term "loss to society" articulated in Taguchi technique, it is more convenient to combine all the criteria taken into account, because the deviation of each criterion from the certain specification will result in a loss. This method is performed via converting criteria to the loss. Therefore, a terminology, total loss to society, is proposed to evaluate the property of the final product. Based on the above method, another method is developed, which is in view of separate analysis of each criterion. This method does not need to integrate all the criteria. Thus, in this method, not only can the whole property be analysed, but the separate property also can be evaluated. Especially when performing optimization under some particular requirement, this method could further demonstrate its advantage.

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