An optimization technique for combined processes of deep-drawing and ironing has been created in order to improve the total process time and cost in manufacturing procedures of axisymmetric components. The initial solution is optimized by means of an algorithm that minimizes the total time of the global process, based on relationship between lengths, diameters, and velocities of each stage of a multistage process and subject to constraints related to the drawing ratio. The enhanced solution offers a significant reduction in time and cost of the global process. The final results, applied to three cases, are compared with experimental results, showing the accuracy of the complete solution. 1. Introduction The industry of metallic components manufacturing requires developments to be more efficient, in particular in the deep-drawing procedures, where it is important to decrease the process times and costs as in mass production. Thus, it is necessary to devise specific algorithms that will satisfy these demands. These algorithms should be based on technological and scientific basis that will provide solutions that are ready for transfering to the industries. The deep-drawing process has been analysed with this objective in mind due to its convenient nature as a global model which includes all stages of the process, namely, drawing, redrawing, and ironing. The majority of literature contributions are focused on the study of properties of process, in particular, the prediction of the limiting drawing ratio [1–3], the blank design using different methodologies, such as parametric NURBS surfaces [4], upper bound method [5], or artificial neural network [6, 7], the effect of die radius on the blank holder force and drawing ratio [8], the predicted thickness distribution of the deep drawn circular cup of stainless steel [9], the improvement of drawability by means of technological parameters [10, 11] or the formability with different thickness [12]. However, some efforts have been realised about the parts design [13] or generation of algorithms, mainly related to the process planning; Ramana and Rao [14] developed a framework based on knowledge related to design-process planning integration for sheet metal components, although there is no evidence of its application. Also, Vosniakos et al. [15] devised an intelligent system to process design of sheet parts. As can be seen, the researches of deep-drawing processes are not focused on the reduction of time, despite frequently being used on mass production due to the characteristics of the parts. This paper presents a
References
[1]
D. K. Leu, “The limiting drawing ratio for plastic instability of the cup-drawing process,” Journal of Materials Processing Technology, vol. 86, no. 1–3, pp. 168–176, 1998.
[2]
P. Sonis, N. V. Reddy, and G. K. Lal, “On multistage deep drawing of axisymmetric components,” Journal of Manufacturing Science and Engineering, vol. 125, no. 2, pp. 352–362, 2003.
[3]
R. K. Verma and S. Chandra, “An improved model for predicting limiting drawing ratio,” Journal of Materials Processing Technology, vol. 172, no. 2, pp. 218–224, 2006.
[4]
R. Padmanabhan, M. C. Oliveira, A. J. Baptista, J. L. Alves, and L. F. Menezes, “Blank design for deep drawn parts using parametric NURBS surfaces,” Journal of Materials Processing Technology, vol. 209, no. 5, pp. 2402–2411, 2009.
[5]
A. Agrawal, N. V. Reddy, and P. M. Dixit, “Determination of optimum process parameters for wrinkle free products in deep drawing process,” Journal of Materials Processing Technology, vol. 191, no. 1–3, pp. 51–54, 2007.
[6]
M. Haddadzadeh, M. R. Razfar, and M. R. M. Mamaghani, “Novel approach to initial blank design in deep drawing using artificial neural network,” Proceedings of the Institution of Mechanical Engineers B: Journal of Engineering Manufacture, vol. 223, no. 10, pp. 1323–1330, 2009.
[7]
A. Chamekh, S. Ben Rhaiem, H. Khaterchi, H. Bel Hadj Salah, and R. Hambli, “An optimization strategy based on a metamodel applied for the prediction of the initial blank shape in a deep drawing process,” International Journal of Advanced Manufacturing Technology, vol. 50, no. 1–4, pp. 93–100, 2010.
[8]
S. Sezek, V. Savas, and B. Aksakal, “Effect of die radius on blank holder force and drawing ratio: A model and experimental investigation,” Materials and Manufacturing Processes, vol. 25, no. 7, pp. 557–564, 2010.
[9]
R. Padmanabhan, M. C. Oliveira, J. L. Alves, and L. F. Menezes, “Influence of process parameters on the deep drawing of stainless steel,” Finite Elements in Analysis and Design, vol. 43, no. 14, pp. 1062–1067, 2007.
[10]
K. Mori and H. Tsuji, “Cold deep drawing of commercial magnesium alloy sheets,” CIRP Annals-Manufacturing Technology, vol. 56, no. 1, pp. 285–288, 2007.
[11]
L. M. A. Hezam, M. A. Hassan, I. M. Hassab-Allah, and M. G. El-Sebaie, “Development of a new process for producing deep square cups through conical dies,” International Journal of Machine Tools and Manufacture, vol. 49, no. 10, pp. 773–780, 2009.
[12]
H. C. Tseng, C. Hung, and C. C. Huang, “An analysis of the formability of aluminum/copper clad metals with different thicknesses by the finite element method and experiment,” International Journal of Advanced Manufacturing Technology, vol. 49, no. 9–12, pp. 1029–1036, 2010.
[13]
B. C. Hwang, S. M. Han, W. B. Bae, and C. Kim, “Development of an automated progressive design system with multiple processes (piercing, bending, and deep drawing) for manufacturing products,” International Journal of Advanced Manufacturing Technology, vol. 43, no. 7-8, pp. 644–653, 2009.
[14]
K. V. Ramana and P. V. M. Rao, “Data and knowledge modeling for design-process planning integration of sheet metal components,” Journal of Intelligent Manufacturing, vol. 15, no. 5, pp. 607–623, 2004.
[15]
G. C. Vosniakos, I. Segredou, and T. Giannakakis, “Logic programming for process planning in the domain of sheet metal forming with progressive dies,” Journal of Intelligent Manufacturing, vol. 16, no. 4-5, pp. 479–497, 2005.
[16]
F. Javier Ramírez and R. Domingo, “Application of an aided system to multi-step deep drawing process in the brass pieces manufacturing,” in Proceedings of the 3rd Manufacturing Engineering Society International Conference, MESIC 2009, pp. 370–379, Alcoy, Spain, June 2009.
[17]
F. J. Ramirez, R. Domingo, and M. A. Sebastian, “Design of an aided system to optimise times and costs in deep drawing process,” in Proceedings of the 2nd IPROMS International Researchers Symposium, vol. 1, pp. 191–196, Ischia, Italy, 2009.
[18]
K. Lange, Handbook of Metal Forming, McGraw-Hill, New York, NY, USA, 1985.
[19]
S. Y. Chung and S. H. Swift, “An experimental investigation into the re-drawing of cylindrical shells,” Proceedings of the Institution of Mechanical Engineers B: Journal of Engineering Manufacture, vol. 1, pp. 437–447, 1975.
[20]
M. A. Sebastián and A. M. Sanchez-Perez, “Dise？o asistido por ordenador de los útiles para la embutición profunda de piezas cilíndricas huecas,” Internal Report, ETSII, UPM, Madrid, Spain, 1980.
[21]
F. J. Ramirez, R. Domingo, M. A. Sebastian, and M. S. Packianather, “The development of competencies in manufacturing engineering by means of a deep-drawing tool,” Journal of Intelligent Manufacturing, vol. 24, no. 3, pp. 457–472, 2011.
[22]
F. J. Ramirez, R. Domingo, and M. A. Sebastian, “A technological model applied to multi-stage deep drawing process of axisymmetric components,” in Proceedings of the 21st International Computer-Aided Production Engineering Conference (CAPE '10), Edinburgh, UK, 2010.
[23]
E. Siebel and H. Beissw？nger, Deep Drawing, Carl Hanser, Munich, Germany, 1995.
[24]
E. M. Rubio, M. Marín, R. Domingo, and M. A. Sebastián, “Analysis of plate drawing processes by the upper bound method using theoretical work-hardening materials,” International Journal of Advanced Manufacturing Technology, vol. 40, no. 3-4, pp. 261–269, 2009.
