Obtaining manufactured geometries of deep-drawn components through a model updating procedure using geometric shape parameters

Abstract

The vibration response of a component or system can be predicted using the finite element method after ensuring numerical models represent realistic behaviour of the actual system under study. One of the methods to build high-fidelity finite element models is through a model updating procedure. In this work, a novel model updating method of deep-drawn components is demonstrated. Since the component is manufactured with a high draw ratio, significant deviations in both profile and thickness distributions occurred in the manufacturing process. A conventional model updating, involving Young's modulus, density and damping ratios, does not lead to a satisfactory match between simulated and experimental results. Hence a new model updating process is proposed, where geometry shape variables are incorporated, by carrying out morphing of the finite element model. This morphing process imitates the changes that occurred during the deep drawing process. An optimization procedure that uses the Global Response Surface Method (GRSM) algorithm to maximize diagonal terms of the Modal Assurance Criterion (MAC) matrix is presented. This optimization results in a more accurate finite element model. The advantage of the proposed methodology is that the CAD surface of the updated finite element model can be readily obtained after optimization. This CAD model can be used for carrying out analysis, as it represents the manufactured part more accurately. Hence, simulations performed using this updated model with an accurate geometry, will therefore yield more reliable results.

Reverse engineering of deep drawn components with an isogeometric framework

“…The resulting MAC matrix is plotted in Figure 5 where a perfect correlation is observed for the first 5 modes, with the accuracy decreasing toward higher frequencies. These results are in agreement with those reported using the traditional FEM approach in [67], where a similar accuracy is obtained.…”

“…The first component considered is an oil-pan look-alike structure that has been employed in previous studies in order to understand the vibration and noise radiation characteristics of this type of components [67,68]. In fact, the radiated noise coming from an oil-pan can have a significant contribution towards the total noise emitted by an automobile engine and it was shown in the literature that oil-pan noise reduction up to 1.5 dB(A) can be achieved by structural optimization [69,70] or through resorting to passive damping treatments.…”

Predictions of the design decisions for vehicle alloy wheel rims using neural network

“…Therefore, the implementation of design by the morphing approach provides time and cost savings for the optimum design outlines for alloy wheel design procedures. 34 Morphing is implemented on the FEM to create the corresponding shape variables. Data were collected using the Latin hypercube and Hammersley methods by considering six design parameters with long computation times for each analysis.…”

Incommensurate vibro-acoustic performance due to in-process blank holder force variation during deep drawing process

“…Dev et al [17] carried out a modal analysis of an oil pan using the geometry obtained from forming simulation results. Balla et al [18] showed that significant changes in the geometry profile and thickness distribution occurred in the single-stage deep-drawn components. They demonstrated that the mode shapes of the physical parts are significantly altered when compared to the base CAD finite element model results.…”