Hybrid optimisation of input process parameters of deep-drawn cylindrical cups from directional rolled copper strips

Deep drawing is a critical manufacturing process in the automobile, aerospace, and packaging industries, widely employed for producing cup-shaped components. This paper provides a comprehensive evaluation of the deep drawing process for cylindrical cups formed from Al1100 and SS202, focusing on the influence of material type, blank diameter (50, 55, 60, and 70 mm), and lubrication conditions. A hybrid approach, combining experimental investigations, Finite Element Analysis (FEA), and the Whale Optimization Algorithm (WOA), was utilized to determine optimal process parameters, including load, compressive strength, and elongation. Experimental results indicated that FEA accurately predicted elongation (20 mm) across all blank diameters but overestimated maximum loads and compressive strengths, particularly for SS202. Lubrication significantly reduced loads and defects while enhancing elongation, although these improvements were not fully captured by FEA simulations. WOA outperformed FEA in predictive accuracy, achieving error margins as low as 1.87% for minimum load and 2.31% for compressive strength. The optimization process identified a 50 mm blank diameter as the most efficient for both the materials, enhancing material utilization and process efficiency. Integrating WOA with FEA yielded valuable insights into defect mitigation, particularly in reducing wrinkling and fractures, thereby improving product quality. This study demonstrates the effectiveness of combining advanced optimization algorithms with simulation tools, promoting sustainable manufacturing by enhancing efficiency and material utilization in deep drawing processes.

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Investigational Analysis on Wire Electrical Discharge Machining of Aluminium Based Composites by Taguchi’s Method

Natarajan,

Pasupuleti,

Kumar

et al. 2023

SAE Technical Paper Series

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<div class="section abstract"><div class="htmlview paragraph">A wide range of engineering domains, such as aeronautical, automobiles, and marine, rely on the use of Metal Matrix Composites (MMC). Due to the excellent properties, such as hardness and strength, Aluminum base MMC are generally adopted in various uses. Due to the increasing number of reinforcement materials being added to the MMC, its properties are expected to improve. In this exploratory analysis, an effort was given to develop a new aluminium-based MMC. The analysis of the machinability of the composite was also performed. The process of creating a new MMC using a stir casting technique was carried out. It resulted in a better and more reinforced composite than its base materials. The reinforcement materials were fabricated using different weight combinations and process parameters, such as the temperature and duration required to stir. Due to the improved properties of the composite, the traditional machining method is not feasible for machining of these materials. Wire Electro-Discharge Machining (WEDM) is commonly used for machining harder materials and especially for making intricate shapes. The machining has been performed through the use of pulse on, a pulse off, and an applied current. The experiments conducted under the supervision of Taguchi are designed to be performed according to the specified parameters and outputs. These variables are considered to be important in improving the performance of the process. Analysis of Variance (ANOVA) has been adopted to examine the significance of the various factors on the preferred output. The results of this study can help the manufacturer improve the performance of the WEDM process.</div></div>

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Hybrid optimisation of input process parameters of deep-drawn cylindrical cups from directional rolled copper strips

Cited by 4 publications

References 32 publications

Optimizing Machining Performance of Heat-Treatable Aluminum Alloys Through MQL Condition Parameter Turning in High-Speed Machining

Optimizing Machining Performance of Heat-Treatable Aluminum Alloys Through MQL Condition Parameter Turning in High-Speed Machining

Experimental and computational optimization of sheet metal forming parameters for cylindrical cups of Al1100 and SS202

Investigational Analysis on Wire Electrical Discharge Machining of Aluminium Based Composites by Taguchi’s Method

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