Advertisement

Development of car wishbone using sheet metal tearing process via the theory of inventive problem-solving (TRIZ) method

  • Nuri ŞenEmail author
  • Yakup Baykal
Technical Paper
  • 116 Downloads

Abstract

In the automotive industry, sheet metal forming process design is of great importance. The cold forming process in particular is the most widely preferred of these methods. In the production of car parts in complex forms, forming problems such as tearing, wrinkling, back spring and unwanted thinning can appear. Recently, numerical analysis technology and software tools have been widely used in process design and metal forming. Elimination of these problems without the use of analysis programs means the use of the trial and error method, which results in much wasted time and huge costs. In addition to the use of analysis programs, resolving problems without mold process and design knowledge is also problematic. In this study, the theory of inventive problem-solving (TRIZ) approach was utilized to reach an analytical solution. In this methodology, the improving and worsening features were determined and a TRIZ 39 × 39 contradiction matrix was created which led to the solutions. Virtual experiments were carried out on a wishbone mold model designed via the Siemens NX 12 CAD program using the Autoform R7 analysis program. Real environment experiments were then performed, and the problem of tearing during the forming process was eliminated. The measured thickness value of this area, which was formed without tearing, was measured as 2.7 mm in the virtual environment experiments and 2.9 mm in the real environment experiments. In addition, the wishbone was subjected to two-axis (x and z) dynamic testing, with acceptable values reached at 500,000 cycles.

Keywords

Sheet metal forming TRIZ FEM 

Notes

Acknowledgements

We would like to thank Teknorot R&D Center for their contributions. We would also like to thank Prof. Dr. Metin O. KAYA for the TRIZ methodology training and his contributions.

References

  1. 1.
    Şen N (2016) “Düzce Üniversitesi Bilim ve Teknoloji Dergisi,” Düzce Üniversitesi Bilim ve Teknoloji Dergisi, vol 4, no Doğadan Esinlenen Optimizasyon Algoritmaları ve Optimizasyon Algoritmalarının Optimizasyonu, pp 293–304Google Scholar
  2. 2.
    Nezami S, Akbari A, Ahangar S (2017) Parametric investigation of pulsating blank holder’s effect in deep drawing process of rectangular Al 1050 cup. J Braz Soc Mech Sci Eng 39(10):4081–4090CrossRefGoogle Scholar
  3. 3.
    Özek C, Bal M (2009) The effect of die/blank holder and punch radiuses on limit drawing ratio in angular deep-drawing dies. Int J Adv Manuf Technol 40(11–12):1077–1083.  https://doi.org/10.1007/s00170-008-1435-3 CrossRefGoogle Scholar
  4. 4.
    Kim Y, Son H, Park J, Choi S, Yang S (2006) Finite element analysis to optimize forming conditions for lower control arm. Metall Mater Trans A 37(8):2539–2547CrossRefGoogle Scholar
  5. 5.
    Altuntaş S, Yener E (2012) An approach based on TRIZ methodology and SERVQUAL scale to improve the quality of health-care service: a case study. Ege Acad Rev 12(1):95–104Google Scholar
  6. 6.
    Kremer GO, Chiu MC, Lin CY, Gupta S, Claudio D, Thevenot H (2012) Application of axiomatic design, TRIZ, and mixed integer programming to develop innovative designs: a locomotive ballast arrangement case study. Int J Adv Manuf Technol 61(5–8):827–842CrossRefGoogle Scholar
  7. 7.
    Azammi AMN, Sapuan SM, Ishak MR, Sultan MTH (2018) Conceptual design of automobile engine rubber mounting composite using TRIZ–morphological chart–analytic network process technique. Def Technol 14(4):268–277CrossRefGoogle Scholar
  8. 8.
    Ekmekci I, Koksal M (2015) TRIZ methodology and an application example for product development. Procedia Soc Behav Sci 195:2689–2698CrossRefGoogle Scholar
  9. 9.
    Mansor MR, Sapuan SM, Zainudin ES, Nuraini AA, Hambali A (2014) Conceptual design of kenaf fiber polymer composite automotive parking brake lever using integrated TRIZ–morphological chart–analytic hierarchy process method. Mater Des 54:473–482CrossRefGoogle Scholar
  10. 10.
    Durgunm İ, Doruk E (2015) Improvement of pedestrian safety conditions in frontal impacted traffic accidents using TRIZ approach. Afyon Kocatepe Üniversitesi Fen ve Mühendislik Bilimleri Dergisi 15:1–6Google Scholar
  11. 11.
    Durgun I, Öztürk Ö, ÖZTÜRK Ü (2013) TRIZ solutıons for the vehicle sliding doors opening problem on cold. In: Uluslararası Katılımlı 16. Üretim Araştırmaları Sempozyumu İstanbul Teknik Üniversitesi - İşletme Fakültesi SOĞUK, 2013, no. OctoberGoogle Scholar
  12. 12.
    Ma WY, Wang BY, Fu L, Zhou J, Huang MD (2015) Effect of friction coefficient in deep drawing of AA6111 sheet at elevated temperatures. Trans Nonferrous Metals Soc China (Engl Ed) 25(7):2342–2351CrossRefGoogle Scholar
  13. 13.
    Sen N, Kurgan N (2016) Improving deep drawability of HC300LA sheet metal by warm forming. Int J Adv Manuf Technol 82(5–8):985–995CrossRefGoogle Scholar

Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2019

Authors and Affiliations

  1. 1.Department of Mechanical Engineering, Faculty of EngineeringDuzce UniversityDüzceTurkey
  2. 2.1. Organize Sanayi BölgesiDüzceTurkey

Personalised recommendations