Springback is the main concern in U-shaped part forming, which would adversely affect desired part geometries. One of the useful methods to solve this problem is to apply reasonable variable binder force. In this study a multi-objective optimization method for the optimization of variable binder force in sheet metal forming was suggested. To solve the optimization problem effectively, a genetic algorithm (GA) coupled with the Response Surface Methodology (RSM) based analytical models has been used. In creating the RS models, FEA results based on D-optimal experimental design method is utilized. The benchmark of the 2D draw bending problem in NUMISHEET’93 has been utilized to validate the method by FEM. The commercial FEA software LS-DYNA was used to perform the forming process simulation. The results obtained from optimization correlates also well with those from FEAs and it is found that proposed optimization methodology can successfully be employed to improve forming conditions and several variable binder force curves which could fulfill different needs are acquired efficiently. |
Abstracts 
