An Optimization Algorithm for Improving Combined Multi-Stage Deep-Drawing and Ironing Processes of Axisymmetric Components. Analysis and Experimentation

Abstract

A new optimization algorithm for combined processes of deep-drawing and ironing has been created in order to improve these types of axisymmetric components manufacturing procedures. The model provides a comprehensive analysis of those phenomena occurring in multi-stage processes of axisymmetric geometry work-pieces. The scientific development starts out from works that provide LDR (limiting drawing ratio) solutions based on normal anisotropy value, strain hardering exponent and others parameters which have just been applied to the drawing and redrawing stages so far. The authors extend this work to the ironing stages, and also provide a global and integral scientific solution for the whole process. At the beginning the algorithm provides an initial solution which is afterwards optimized by means of objective functions and constraints. The resolution of the optimization process is carried out by a recursive function that minimizes the total time of the global process. The enhanced solution performs a significant reduction in time and costs of the process. The model allows the modification and correction of certain process variables in order to predict the impact of those that are not fully controllable. The final results are compared using experimental results obtained by the authors, so as to show the reliability of the complete solution.