Abstract
In this research, the process of electromagnetic tube compression forming was simulated primarily through the sequential-coupled method. The Taguchi method and signal-to-noise analysis were employed to investigate the three effective parameters of the discharge voltage, the thickness of the work piece, and the clearance between the die and the work piece on the depth of bead in this process. The Johnson–Cook damage criterion which usually applies to high strain rate processes was used to predict tearing. The impact of the aforementioned parameters on the Johnson–Cook damage was evaluated by using signal-to-noise analysis. Discharge voltage and the thickness of the work piece, regarding the depth of bead and the Johnson–Cook damage, were significant, while clearance between the die and the work piece had the least influence compared to the other two parameters. Experimental tests were carried out to verify the validation of the results. The simulation results obtained from employing the sequential-coupled method for the depth of bead were 5 % higher than the experimental results. Each objective function of the maximum depth of bead and the Johnson-Cook damage was optimized separately. Finally, the aforementioned two objective functions were optimized at the same time using the method of non-dominated sorting genetic algorithm (NSGA-II). The genetic algorithm method created an optimal and safe area against tearing which is referred to as the Pareto front. This study proposed the amounts of the depth of bead which ranges between 4 and 4.45 mm, with a high safety factor (the extent of Johnson–Cook damage 0.65–0.8).
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Shabanpour, M., Fallahi Arezoodar, A. Multi-objective optimization of the depth of bead and tearing in electromagnetic tube compression forming. Int J Adv Manuf Technol 87, 867–875 (2016). https://doi.org/10.1007/s00170-016-8519-2
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DOI: https://doi.org/10.1007/s00170-016-8519-2