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The overall objective of this research project is to define and validate an innovative approach to product stamping and process optimisation in the sheet metal forming field, in which innovative and reliable simulation tools for the virtual stamping prototype, the finite element method (FEM), are linked together with:

-New offline process optimisation techniques, based on statistical approaches and able to take into account the natural variability of the material properties, the robust engineering design (RED).

-Efficient and reliable techniques for the best sampling of the process variable fields, the design of experiment (DOE).

-New approaches to the evaluation of the stamping result, based on the concept of quality functions (QFs), including in-service performance QFs.

Three components were selected by the partners to analyse the feasibility of the approach and improvement allowed on the design stage. The mechanical properties of the material were selected as noise factors (NFs), with respect to which the lower sensitivity of the QF was wished, while process variables were selected as control factors (CFs), with respect to which the QF was optimised.

Two classes of RED approaches were used, the Taguchi method and the dual surface response method, but the better-known Taguchi approach was privileged.

The first geometry (GEOM.1), a cross member, was selected just to verify the feasibility of the approach. The other two components (GEOM.2 and GEOM.3) were analysed in detail, using reliable QFs, specifically developed and validated in the project.he project.

Additional information

Authors: RUTHVEN A, CORUS RD&T, Welsh Technology Centre, Port Talbot Works, West Glamorgan (UK);HUGHES D, CORUS RD&T, Welsh Technology Centre, Port Talbot Works, West Glamorgan (UK);PLACIDI F, CSM, Rome (IT);PIETROSANTI C, CSM, Rome (IT)
Bibliographic Reference: EUR 19984 EN (2001), pp. 210. Euro: 31.00
Availability: Available from EUR-OP sales agent URL:
ISBN: ISBN 92-894-1585-1
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