【導讀】程設計出一個能標示沒有開裂和皺紋的安全區(qū)的可行的成形性圖。成形性圖，有限元分析工藝參數(shù)的組合，應與正交實驗設計陣列相對應。在對成形極限圖鐵的分析結(jié)果的基礎(chǔ)上，將開裂和皺紋的特征值進行了評估。汽車板件的沖壓過程，包括支持諸。一個與有限元仿真結(jié)果的實驗比較表明，通過可行的成形性圖進行沖壓工。藝流程設計是有效的，符合實際進程的。師的指導下進行的研究工作及取得的成果。盡我所知，除文中特別加。而使用過的材料。不包含任何其他個人或集體已經(jīng)發(fā)表或撰寫的成果作品。究做出重要貢獻的個人和集體，均已在文中以明確方式標明。全意識到本聲明的法律后果由本人承擔。同意學校保留并向國家有關(guān)部門或機構(gòu)送交論文的復印件和電子版，允許論文被查閱和借閱。涉密論文按學校規(guī)定處理。沖壓技術(shù)已經(jīng)廣泛應用于汽車行業(yè)。際工業(yè)應用軟件帶來了一些問題的有限元分析結(jié)合優(yōu)化設計的兩種方法。李和許[8]提出一個用可逆有限元方法預測坯料形狀的方

　　

【正文】 g [13]. Their proposed algorithm was applied for the optimization of process variables, such as the blank holding force and the draw bead restraining force. Naceur et al. [14] designed the optimal blank shapes of outer panels of hoods in order to avoid the risk of fracture and wrinkle. In reviewing the above literature, it is clear that design methods that bine FEanalysis and optimization methods, such as the design of experiments, response surface methodology, geic algorithms, and artificial neural works (ANN), are a powerful and useful tool for designing the process of stamping. However, most of the optimal design procedures mentioned above may require repeated FEsimulation with different binations of process variables again, if one of process conditions is changed. It is also a little difficult and plicated for engineers in the industrial field to determine optimal process variables. Therefore, it is worth studying the optimal design of processes under the simultaneous consideration of main process variables, such as the initial blank shape, blank holding force, and draw bead restraining force, in stamping processes owing to a lack of research that is related to this problem. The objective of this study is to propose a method of process design that uses a feasible formability diagram for the effective and rapid design of stamping processes. The feasible formability proposed in this study provides the range of process variables without fracture and wrinkle in actual stamping process. It does not need to repeat the optimization of process design for changed process variables. The process variables considered in this study are the blank size, the blank holding force (BHF), and the height and shoulder radius of the draw bead. To determine the feasible formability diagram, FEanalyses are performed for binations of process variables that correspond to the orthogonal array of design of experiments. Subsequently, the characteristic values for fracture and wrinkle are estimated from the results of FEanalyses on the basis of the forming limit diagram (FLD). The characteristic values for all binations within a whole range of process variables are predicted through the training of an artificial neural work (ANN) [15]. The feasible formability diagram to denote the safe region without defects is finally determined for all binations of process variables. The stamping processes of automotive panels to support suspension module, such as the turret suspension and the wheel house, are taken as examples to verify the effectiveness of process design through feasible formability diagram. The results from FEsimulation are pared with the experimental results. 2. Process design through feasible formability diagram . Process variables In the design of the stamping process, while some process parameters, such as material properties and lubricant conditions, cannot be controlled by the designer, other parameters, such as the blank size, the blank holding force, and the layout of the draw bead, can be controlled [7]. If the controllable parameters are not chosen properly, the stamping process may produce products with defects, such as fracture and wrinkle. Therefore, these controllable parameters are considered as process variables in this study. The first process variable, viz., the initial shape of the blank, has an influence on the material flow into the die cavity during the stamping process. The traditionally optimal shape of blank is referred to as the initial shape of blank for producing a desired shape by which either the trimming process is pletely eliminated or the trimming allowance is minimized. However, in order to guarantee not only a geometrical shape but also a sound quality of the product, the optimal shape of blank should be determined in light of the blank holding force and the draw bead, particularly for the stamping of plex automotive panels. The optimal shape of blank may be changed in case the required blank holding force exceeds the capacities of presses in actual industry and/or a draw bead is added. Therefore, in the design of the optimal shape of blank, it is very plex and difficult to incorporate the influence of process variables, such as the blank holding force and the draw bead, because the optimal shape of blank is dependent on the process variables. The initial shape of blank in this study is designed by the following procedure. The target contour is defined as the shape with a uniform trimming width at the outline of the final product. A mercial FEsoftware, LSDYNA, is used to trial FEsimulation using an arbitrary rectangularshaped blank. After the contour of the deformed rectangular blank is pared with the target contour, the nodal points on the outline of the considered initial blank at the current step are repositioned by the use of the inverse approach of the LSDYNA postprocessor (DYNAFORM) in order to make the deformed contour coincide with the target contour. After the modification of the blank shape, FEsimulation of the deformation process is repeatedly performed, as shown in Fig. 1a, until the shape error is within a specified tolerance assumed to be 10?3 in this study. The formula for the error is given below: (1) where E is the shape error and A T and A D are the areas of the target and deformed contours, respectively. Fig. 1. Design of the initial blank. As mentioned above, the optimal shape of blank is dependent on the process variables. To determine the feasible shape of blank, the contour of the initial blank obtained from Eq. (1) is offset by a uniform distance along the normal direction of the contour. The lower and upper bounds on the offset distance of the blank are the blank shape to bee the target contour after stamping and the blank shape to be enlarged up to the end of