Approach for an automatic optimisation of production chain as a tool for intelligent manufacturing in metal forming

Approach for an automatic optimisation of production chain as a tool for intelligent manufacturing in metal forming

Adam Legwand, Konrad Perzyński, Łukasz Madej, Maciej Pietrzyk

AGH University of Science and Technology, Krakow, Poland.

DOI:

https://doi.org/10.7494/cmms.2014.1.0476

Abstract:

The objective of the paper is development of an automatic system for optimisation of production chains in metalforming. Product properties and their uniform distribution are usually the key parameters for formulation of the objective function in the optimization problem. Such parameters as strain/stress or final grain size distribution significantly influence material behaviour under exploitation conditions, therefore, theoretical prediction of those variables is inevitable for the optimization of the manufacturing chain. Thus, the main focus in the paper is on description of the developed complex tool capable of realization of automatic optimisation for subsequent manufacturing stages. Description of particular components responsible for automatic geometrical model generation, incorporation into the finite element (FE) software, optimisation operations and finally data transfer between subsequent modules are described in detail. A rod rolling operations of elliptical profiles were selected as case studies to demonstrate system capabilities.

Cite as:

Legwand, A., Perzyński, K., Madej, Ł., & Pietrzyk, M. (2014). Approach for an automatic optimisation of production chain as a tool for intelligent manufacturing in metal forming. Computer Methods in Materials Science, 14(1), 64 – 74. https://doi.org/10.7494/cmms.2014.1.0476

Article (PDF):

Keywords:

Optimization, Modelling, Finite element method

Publication dates:

Received: 19.08.2013, accepted: 28.12.2013, published:

Publication type:

Original scientific paper

References:

Bariani, P. F., Bruschi, S., Ghiotti, A., 2007, Material testing and physical simulation in modelling process chains based on forging operations, Computer Methods in Materials Science, 7, 378-382.

Beladi, H., Adachi, Y., Timokhina, I., Hodgson, P. D., 2009, Crystallographic analysis of nanobainitic steels, Scripta Materialia, 60, 455-458.

Bruccoleri, M., Lo Nigro, G., Perrone, G., Renna, P., Noto La

Diega, S., 2005, Production planning in reconfigurable enterprises and reconfigurable manufacturing systems, Annals of the CIRP, 54, 433-436.

Feng, C., Gao, X. N., Tang, Y. T., Zhang, Y., 2013, Comparative life cycle environmental assessment of flue gas desulphurization technologies in China, Journal of Cleaner Production, in press.

Hon, K. K. B., Xu, S., 2007, Impact of product life cycle on manufacturing systems reconfiguration, Annals of the CIRP, 56, 455-458.

Legwand, A., Perzynski, K., 2012, New numerical software approach with shape optimization applied on the landing gear used in construction of ultralight airplanes, Zeszyty Studenckiego Towarzystwa Naukowego, 25, 181-187.

Madej, L., Szeliga, D., Kuziak, R., Pietrzyk, M., 2007, Physical and numerical modelling of forging accounting for exploitation properties of products, Computer Methods in Material Science, 7, 397-405. – 73

Muszka, K., Sun, L., Wynne, B. P., Palmiere, E. J., Rainforth, W.M., 2012, On the effect of strain reversal on static recrystallisation and strain-induced precipitation process kinetics in microalloyed steels, Materials Science Forum, 715-716, 655-660.

Nedler, J. A., Meadf, R., 1965, A simplex method for function minimization, The Computer Journal, 7(4), 308-313.

Pereira, J., Paulre, B., 2001, Flexibility in manufacturing systems: a relational and a dynamic approach, European J. Operational Research, 130, 70-82.

Pietrzyk, M., 2001, Identification of Parameters in the History Dependent Constitutive Model for Steels, Annals of the CIRP, 50, 161-164.

Pietrzyk, M., Kedzierski, Z., Kusiak, H., Madej, W., Lenard J. G., 1993, Evolution of the Microstructure in the Hot Rolling Process, Steel Research International, 64, 549- 556.

Pietrzyk, M., Kuziak, R., 2004, Development of the Constitutive Law for Microalloyed Steels Deformed in the Two- Phase Range of Temperatures, Steel GRIPS, 2, 465-470.

Pietrzyk, M., Lenard, J. G., Dalton, G. M., 1993, A Study of the Plane Strain Compression Test, Annals CIRP, 42, 331- 334.

Pietrzyk, M., Madej, L., Kuziak, R., 2010, Optimal design of manufacturing chain based on forging for copper alloys, with product properties being the objective function, The CIRP Annals, 59, 319-322.

Rauch, L., Madej, L., Weglarczyk, S., Pietrzyk, M., 2008, System for design of the manufacturing process of connecting parts for automotive industry, Archives of Civil and Mechanical Engineering, 8, 157-165.

Robertson, L. T., Hilditch, T. B., Hodgson, P. D., 2008, The effect of prestrain and bake hardening on the low-cycle fatigue properties of TRIP steel, International Journal of Fatigue, 30, 587-594.

Senkov, O. N., Miracle, D. B., Firstov, S. A., 2004, Metalic Materials with high structural efficiency, NATO Science Series – Mathematics, Physics and Chemistry, 146.

Timokhina, I. B., Hodgson, P. D., Ringer, S. P., Zheng, R. K.,

Pereloma, E. V., 2007, Precipitate characterisation of an advanced high-strength low-alloy (HSLA) steel using atom probe tomography, Scripta Materialia, 56, 601- 604. C