Optimization of Springback Prediction in U-Channel Process Using Response Surface Methodology
There is not much effective guideline on development of design parameters selection on spring back for advanced high strength steel sheet metal in U-channel process during cold forming process. This paper presents the development of predictive model for spring back in U-channel process on advanced high strength steel sheet employing Response Surface Methodology (RSM). The experimental was performed on dual phase steel sheet, DP590 in Uchannel forming process while design of experiment (DoE) approach was used to investigates the effects of four factors namely blank holder force (BHF), clearance (C) and punch travel (Tp) and rolling direction (R) were used as input parameters using two level values by applying Full Factorial design (24 ). From a statistical analysis of variant (ANOVA), result showed that blank holder force (BHF), clearance (C) and punch travel (Tp) displayed significant effect on spring back of flange angle (β2 ) and wall opening angle (β1 ), while rolling direction (R) factor is insignificant. The significant parameters are optimized in order to reduce the spring back behavior using Central Composite Design (CCD) in RSM and the optimum parameters were determined. A regression model for spring back was developed. The effect of individual parameters and their response was also evaluated. The results obtained from optimum model are in agreement with the experimental values.
[1] N. Woellner, S. F. Lajarin, and P. V. P. Marcondes, "Blank Holder Force
Influence On The Springback Of Advanced High Strength Steels," in
International Congress of Mechanical Engineering, Ribeirão Preto, SP,
Brazil, 2013.
[2] Z. T. Zhang and D. Lee, "Effects of process variables and material
properties on the springback behavior of 2D-draw bending parts,"
Automotive Stamping Technology, SAE, pp. 11-18, 1995.
[3] D. G. Seo, S. H. Chang, and S. M. Lee, "Springback Characteristics of
Steel Sheets for Warm U-Draw Bending," Metals And Materials
International, vol. 9, p. 5, 2003.
[4] W. D. Cardena, L. M. Genga, and D. K. Matlockb, "Measurement of
Springback," International Journal of Mechanical Sciences, 2002.
[5] J. R. Cho, S. J. Moon, Y. H. Moon, and S. S. Kang, "Finite element
investigation on spring-back characteristics in sheet metal U-bending
process" vol. 141, 2003.
[6] M. Samuel, "Experimental and numerical prediction of springback and
side wall curl in U-bendings of anisotropic sheet metals," Journal of
Materials Processing Technology, vol. 105, pp. 382-393, 2000.
[7] K. Chen, J. P. Lin, M. K. Lv, and L. Y. Wang, "Advanced High Strength
Steel Sheet Forming and Springback Simulation," Advanced Materials
Research, vol. 97-101, pp. 200-203, 2010.
[8] S. K. Panthi, N. Ramakrishnan, A. Meraj, S. S. Shambhavi, and M. D.
Goel, "Finite Element Analysis of sheet metal bending process to predict
the springback," Materials and Design, vol. 31, pp. 657-662, 2010.
[9] P. Chen and M. Koç, "Simulation of springback variation in forming of
advanced high strength steels," Journal of Materials Processing
Technology, vol. 190, pp. 189-198, 2007.
[10] R. Srinivasan, D. Vasudevan, and P. Padmanabhan, "Application of
response surface methodology for predicting springback in air bending
of electro galvanised steel sheets," Int. J. Materials Engineering
Innovation, vol. 4, 2013.
[11] A. Asgari, M. Pereira, B. Rolfe, M. Dingle, and P. Hodgson, "Design of
experiments and springback prediction for AHSS automotive
components with complex geometry," 2005.
[12] R. Bahloul, S. Ben-Elechi, and A. Potiron, "Optimisation of springback
predicted by experimental and numerical approach by using response
surface methodology," Journal of Materials Processing Technology, vol.
173, pp. 101-110, 2006.
[13] K. Karthikeyan, K. Nanthakumar, K. Shanthi, and P.
Lakshmanaperumalsamy, "Response surface methodology for
optimization of culture conditions for dye decolorization by a fungus,
Aspergillus niger HM11 isolated from dye affected soil," Iranian
Journal of Microbiology, vol. 2, pp. 213-222, 2010.
[14] A. Makinouchi, E. Nakamachi, E. Onate, and R. H. Wagoner, " In
Proceedings of the 2th international conference and workshop on
numerical simulation of 3D sheet metal forming processes - " in
NUMISHEET1993, Isehara, Japan, 1993.
[15] R. Plackett and J. Burman, "The design of optimum multifactorial
experiments," Biometrica, vol. 33 pp. 305-325, 1946.
[16] L. Low, T. Teng, A. M. Alkarkhi, A. Ahmad, and N. Morad,
"Optimization of the Adsorption Conditions for the Decolorization and
COD Reduction of Methylene Blue Aqueous Solution using Low-Cost
Adsorbent," Water, Air, & Soil Pollution, vol. 214, pp. 185-195, 2011.
[17] K.T. Chiang, C.C. Chou, and N.M. Liu, "Application of response surface
methodology in describing the thermal performances of a pin-fin heat
sink," International Journal of Thermal Sciences, vol. 48, pp. 1196-
1205, 2009.
[1] N. Woellner, S. F. Lajarin, and P. V. P. Marcondes, "Blank Holder Force
Influence On The Springback Of Advanced High Strength Steels," in
International Congress of Mechanical Engineering, Ribeirão Preto, SP,
Brazil, 2013.
[2] Z. T. Zhang and D. Lee, "Effects of process variables and material
properties on the springback behavior of 2D-draw bending parts,"
Automotive Stamping Technology, SAE, pp. 11-18, 1995.
[3] D. G. Seo, S. H. Chang, and S. M. Lee, "Springback Characteristics of
Steel Sheets for Warm U-Draw Bending," Metals And Materials
International, vol. 9, p. 5, 2003.
[4] W. D. Cardena, L. M. Genga, and D. K. Matlockb, "Measurement of
Springback," International Journal of Mechanical Sciences, 2002.
[5] J. R. Cho, S. J. Moon, Y. H. Moon, and S. S. Kang, "Finite element
investigation on spring-back characteristics in sheet metal U-bending
process" vol. 141, 2003.
[6] M. Samuel, "Experimental and numerical prediction of springback and
side wall curl in U-bendings of anisotropic sheet metals," Journal of
Materials Processing Technology, vol. 105, pp. 382-393, 2000.
[7] K. Chen, J. P. Lin, M. K. Lv, and L. Y. Wang, "Advanced High Strength
Steel Sheet Forming and Springback Simulation," Advanced Materials
Research, vol. 97-101, pp. 200-203, 2010.
[8] S. K. Panthi, N. Ramakrishnan, A. Meraj, S. S. Shambhavi, and M. D.
Goel, "Finite Element Analysis of sheet metal bending process to predict
the springback," Materials and Design, vol. 31, pp. 657-662, 2010.
[9] P. Chen and M. Koç, "Simulation of springback variation in forming of
advanced high strength steels," Journal of Materials Processing
Technology, vol. 190, pp. 189-198, 2007.
[10] R. Srinivasan, D. Vasudevan, and P. Padmanabhan, "Application of
response surface methodology for predicting springback in air bending
of electro galvanised steel sheets," Int. J. Materials Engineering
Innovation, vol. 4, 2013.
[11] A. Asgari, M. Pereira, B. Rolfe, M. Dingle, and P. Hodgson, "Design of
experiments and springback prediction for AHSS automotive
components with complex geometry," 2005.
[12] R. Bahloul, S. Ben-Elechi, and A. Potiron, "Optimisation of springback
predicted by experimental and numerical approach by using response
surface methodology," Journal of Materials Processing Technology, vol.
173, pp. 101-110, 2006.
[13] K. Karthikeyan, K. Nanthakumar, K. Shanthi, and P.
Lakshmanaperumalsamy, "Response surface methodology for
optimization of culture conditions for dye decolorization by a fungus,
Aspergillus niger HM11 isolated from dye affected soil," Iranian
Journal of Microbiology, vol. 2, pp. 213-222, 2010.
[14] A. Makinouchi, E. Nakamachi, E. Onate, and R. H. Wagoner, " In
Proceedings of the 2th international conference and workshop on
numerical simulation of 3D sheet metal forming processes - " in
NUMISHEET1993, Isehara, Japan, 1993.
[15] R. Plackett and J. Burman, "The design of optimum multifactorial
experiments," Biometrica, vol. 33 pp. 305-325, 1946.
[16] L. Low, T. Teng, A. M. Alkarkhi, A. Ahmad, and N. Morad,
"Optimization of the Adsorption Conditions for the Decolorization and
COD Reduction of Methylene Blue Aqueous Solution using Low-Cost
Adsorbent," Water, Air, & Soil Pollution, vol. 214, pp. 185-195, 2011.
[17] K.T. Chiang, C.C. Chou, and N.M. Liu, "Application of response surface
methodology in describing the thermal performances of a pin-fin heat
sink," International Journal of Thermal Sciences, vol. 48, pp. 1196-
1205, 2009.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:70262", author = "Muhamad Sani Buang and Shahrul Azam Abdullah and Juri Saedon", title = "Optimization of Springback Prediction in U-Channel Process Using Response Surface Methodology ", abstract = "There is not much effective guideline on development of design parameters selection on spring back for advanced high strength steel sheet metal in U-channel process during cold forming process. This paper presents the development of predictive model for spring back in U-channel process on advanced high strength steel sheet employing Response Surface Methodology (RSM). The experimental was performed on dual phase steel sheet, DP590 in Uchannel forming process while design of experiment (DoE) approach was used to investigates the effects of four factors namely blank holder force (BHF), clearance (C) and punch travel (Tp) and rolling direction (R) were used as input parameters using two level values by applying Full Factorial design (24 ). From a statistical analysis of variant (ANOVA), result showed that blank holder force (BHF), clearance (C) and punch travel (Tp) displayed significant effect on spring back of flange angle (β2 ) and wall opening angle (β1 ), while rolling direction (R) factor is insignificant. The significant parameters are optimized in order to reduce the spring back behavior using Central Composite Design (CCD) in RSM and the optimum parameters were determined. A regression model for spring back was developed. The effect of individual parameters and their response was also evaluated. The results obtained from optimum model are in agreement with the experimental values.
", keywords = "Advance high strength steel, U-channel process,
Springback, Design of Experiment, Optimization, Response Surface
Methodology (RSM). ", volume = "9", number = "7", pages = "1220-8", }
