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Multi-Objective Six-Sigma Approach for Robust Optimization of Multi-Point Dieless Forming Process

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Abstract

The significance of the stochastic nature of a multi-point dieless forming (MDF) process for final product accuracy has been extensively recognized. It is an under-research area in terms of effective techniques and computational tools for easy industrial applications and implementation. It is also recognized that wrinkling and dimpling are the most MDF product defects. Deterministic optimization using the finite element (FE) analysis have been used to improve the formability of the MDF process; however, not considering the noises of the system could affect the variation of the final product quality. In this study, the uncertainty parameters are considered to avoid the random variation of the final product accuracy while using the same control process parameters. In addition, to avoiding computationally expensive FE analysis, the approximation model has been used for both product defects. A six-sigma robust optimization is applied to obtain both reliable and robust MDF products. Finally a numerical simulation with one experimental result of a given target shape shows that the wrinkling and dimpling defect is controlled using the obtained optimal process parameter setup.

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Acknowledgements

This study was financially supported by the \(\ulcorner\)2018 Post-Doc. Development Program\(\lrcorner\) of Pusan National University. Also, this work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korea government(MSIT) (No.2019R1A5A6099595).

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Authors and Affiliations

  1. Department of Aerospace Engineering, Pusan National University, Busan, 46241, South Korea

    Misganaw Abebe, Junseok Yoon & Beom-Soo Kang

  2. Materials Deformation Department, Korea Institute of Materials Science, 797, Changwon-daero, Seongsan-gu, Changwon-si, Gyeongsangnam-do, 51508, South Korea

    Junseok Yoon

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  1. Misganaw Abebe
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Correspondence to Beom-Soo Kang.

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Appendix: Design of Experiment

Appendix: Design of Experiment

See Tables 9 and 10.

Table 9 Sample for training
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Table 10 Sample for testing
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Abebe, M., Yoon, J. & Kang, BS. Multi-Objective Six-Sigma Approach for Robust Optimization of Multi-Point Dieless Forming Process. Int. J. Precis. Eng. Manuf. 21, 1791–1806 (2020). https://doi.org/10.1007/s12541-020-00373-1

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