Multi-objective optimization of forming parameters for tube hydroforming process based on the Taguchi method

Abstract

Tube hydroforming is an attractive manufacturing technology which is now widely used in many industries, especially the automobile industry. The purpose of this study is to develop a method to analyze the effects of the forming parameters on the quality of part formability and determine the optimal combination of the forming parameters for the process. The effects of the forming parameters on the tube hydroforming process are studied by finite element analysis and the Taguchi method. The Taguchi method is applied to design an orthogonal experimental array, and the virtual experiments are analyzed by the use of the finite element method (FEM). The predicted results are then analyzed by the use of the Taguchi method from which the effect of each parameter on the hydroformed tube is given. In this work, a free bulging tube hydroforming process is employed to find the optimal forming parameters combination for the highest bulge ratio and the lowest thinning ratio. A multiobjective optimization approach is proposed by simultaneously maximizing the bulge ratio and minimizing the thinning ratio. The optimization problem is solved by using a goal attainment method. An example is given to illustrate the practicality of this approach and ease of use by the designers and process engineers.

The multi-objective robust optimization of the loading path in the T-shape tube hydroforming based on dual response surface model

“…In this study, NSGA-II [46] is employed to solve Eq. (14). Because NSGA-II is a well-studied optimization algorithm, the description of the determination of the proper parameters for a NSGA-II operation can be referred to reference [46].…”

“…Yang et al [12] dealt with sensitivities analysis and optimal process design of the THF process using the finite Fann and Hsiao [13] proposed an optimization strategy based on conjugate gradient method and FEM to determine the optimal loading path in the THF process, and they also pointed out that the loading path generated by sequential mode is better than that generated by the batch mode. Li et al [14] developed a method to analyze the effect of the material properties, geometric characteristics, and loading parameters on the product quality using Taguchi method and FEM, and the optimal combination of the internal pressure and the friction coefficient was obtained by using goal attainment method. Ben and EI [15] provided a deep comparison between the quadratic polynomial response surface (RS) model and radial basis function (RBF) as surrogate techniques to construct surrogate models for global sensitivities and multi-objective optimization of the THF process, and they found that the RBF showed its superiority over the quadratic polynomial RS model to deal with nonlinearities proved through analytical test function and practical THF process.…”

Application of Taguchi approach on investigation of formability for perforated Al 8011 sheets

“…Conducting Taguchi experiments in terms of orthogonal array allows the effects of several parameters efficiently. The treatment of experimental results is based on the analysis of variance (ANOVA) Taguchi and Konishi, 1987;Taguchi, 1993;Ko et al, 1999;Li et al, 2006). Mahapatra and Chaturvedi (2009) made an attempt has been made to study the abrasive behaviour of untreated sugarcane fibre reinforced composites in a simplified manner and develop empirical model.…”

Simulation and optimization of hot extrusion process to produce rectangular waveguides

“…Lee and Yang [11] studied the influencing parameters affecting the springback in the sheet metal forming process by using explicit finite element analysis and the Taguchi method. Tube hydroforming process [12], bend forming process [13], and power spinning process [14] are other metal forming processes in which the Taguchi method was used to design their experiments and optimize their significant parameters. Hsiang et al [15] investigated the relationship between the multiple performance characteristics index (MPCI) and process parameters for the hot extrusion process of magnesium alloy sheets using the Taguchi method.…”