Optimization of conventional spinning process parameters by means of numerical simulation and statistical analysis

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@article{feb9365c9ed747f0843364045c12c839,
title = "Optimization of conventional spinning process parameters by means of numerical simulation and statistical analysis",
abstract = "Research in sheet metal spinning has increased due to a greater demand, especially in the transportation industries, for parts with very high strength-to-weight ratios with low cost. Spinning processes are efficient in producing such characteristics and there is great flexibility in the process with a relatively low tool cost. The objectives of this investigation are to define the critical working parameters in spinning, show the effects of these factors on product quality characteristics, and to optimize the working parameters. The example used is the conventional spinning of a cylindrical cup. Optimization of the process is undertaken through the use of statistical analysis tools applied to the data produced from three-dimensional finite element simulations of the process. This has been achieved by generating two {\textquoteleft}designs of experiments{\textquoteright}.The first identifies the most critical parameters for product formability and the second shows how these critical parameters affect the product quality. The results show that feed rate,relative clearance, and roller nose radius are the most important working parameters and significantly affect average thickness, thickness variation, and springback of the cylindrical cup. An additional 22 per cent improvement in the product quality characteristic is gained through using the optimum working parameters.",
keywords = "statistical analysis, optimization, design of experiments, conventional spinning, finite element modelling",
author = "Khamis Essa and Peter Hartley",
year = "2010",
month = jan,
day = "1",
doi = "10.1243/09544054JEM1786",
language = "English",
volume = "224",
pages = "1691--1705",
journal = "Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture",
issn = "0954-4054",
publisher = "SAGE Publications",
number = "B11",

}

RIS

TY - JOUR

T1 - Optimization of conventional spinning process parameters by means of numerical simulation and statistical analysis

AU - Essa, Khamis

AU - Hartley, Peter

PY - 2010/1/1

Y1 - 2010/1/1

N2 - Research in sheet metal spinning has increased due to a greater demand, especially in the transportation industries, for parts with very high strength-to-weight ratios with low cost. Spinning processes are efficient in producing such characteristics and there is great flexibility in the process with a relatively low tool cost. The objectives of this investigation are to define the critical working parameters in spinning, show the effects of these factors on product quality characteristics, and to optimize the working parameters. The example used is the conventional spinning of a cylindrical cup. Optimization of the process is undertaken through the use of statistical analysis tools applied to the data produced from three-dimensional finite element simulations of the process. This has been achieved by generating two ‘designs of experiments’.The first identifies the most critical parameters for product formability and the second shows how these critical parameters affect the product quality. The results show that feed rate,relative clearance, and roller nose radius are the most important working parameters and significantly affect average thickness, thickness variation, and springback of the cylindrical cup. An additional 22 per cent improvement in the product quality characteristic is gained through using the optimum working parameters.

AB - Research in sheet metal spinning has increased due to a greater demand, especially in the transportation industries, for parts with very high strength-to-weight ratios with low cost. Spinning processes are efficient in producing such characteristics and there is great flexibility in the process with a relatively low tool cost. The objectives of this investigation are to define the critical working parameters in spinning, show the effects of these factors on product quality characteristics, and to optimize the working parameters. The example used is the conventional spinning of a cylindrical cup. Optimization of the process is undertaken through the use of statistical analysis tools applied to the data produced from three-dimensional finite element simulations of the process. This has been achieved by generating two ‘designs of experiments’.The first identifies the most critical parameters for product formability and the second shows how these critical parameters affect the product quality. The results show that feed rate,relative clearance, and roller nose radius are the most important working parameters and significantly affect average thickness, thickness variation, and springback of the cylindrical cup. An additional 22 per cent improvement in the product quality characteristic is gained through using the optimum working parameters.

KW - statistical analysis

KW - optimization

KW - design of experiments

KW - conventional spinning

KW - finite element modelling

U2 - 10.1243/09544054JEM1786

DO - 10.1243/09544054JEM1786

M3 - Article

VL - 224

SP - 1691

EP - 1705

JO - Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture

JF - Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture

SN - 0954-4054

IS - B11

ER -