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54th CIRP Conference on Manufacturing Systems

54th CIRP Conference on Manufacturing Systems
Evolutionary optimization of deep-drawing processes on servo screw presses
Evolutionary optimization 28th CIRP of deep-drawing
Design Conference, May processes Nantes, on
2018, motion servo screw presses
France
with freely programmable force and functions
with freely programmable force and motion functions
A new
Sebastianmethodology
Kriechenbauerto a,∗, analyze
a,∗
Peter Müller the
a
functional
a , Reinhard Mauermannand physicala
architecture
a , Welf-Guntram Drossela,b of
Sebastian Kriechenbauer , Peter Müller , Reinhard Mauermann , Welf-Guntram Drossela,b
existing
b products
Technische Universität
a

Chemnitz,
for
Institut
an assembly
Tools and Forming
Werkzeugmaschinen
oriented product
Technology IWU, Nöthnitzer
und Produktionsprozesse, ProfessurStraße
family
44, 01187
Adaptronik
identification
Fraunhofer Institute for Machine Tools and Forming Technology IWU, Nöthnitzer Straße 44, 01187 Dresden, Germany
a
Fraunhofer Institute forfür
Machine und Dresden, Germany 09107 Chemnitz,
Funktionsleichtbau,
b Technische
Universität Chemnitz, Institut für Werkzeugmaschinen und Produktionsprozesse, Professur Adaptronik und Funktionsleichtbau, 09107 Chemnitz,
Germany
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
Germany
* Corresponding Author. Tel.: +49-351-4772-2338. Fax: +49-351-4772-2338-3. E-mail Address: sebastian.kriechenbauer@iwu.fraunhofer.de
* Corresponding Author. Tel.: +49-351-4772-2338. Fax: +49-351-4772-2338-3. E-mail Address: sebastian.kriechenbauer@iwu.fraunhofer.de
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France

*Abstract
Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu
Abstract
Servo screw presses with freely programmable force and motion functions lead to innovative forming technologies for deep drawing of sheet
Servo
metals.screw presses with
The advanced freely programmable
application potential of the force and motion
machine type is functions
mainly basedlead on
to innovative
the accuracy forming technologies
and flexibility. Due for deep
to the drawing
increase of of sheet
process
metals.
parametersTheinadvanced application
deep-drawing potential
processes with of the machine
variable force and typemotion
is mainly based on
functions, thethe accuracyforand
standards flexibility.
method Due (consideration
planning to the increaseofofmachine
process
Abstract
parameters in deep-drawing of processes with variable forceinand motion functions, the standards for method planning (consideration
properties, parameterization the movement functions) comparison to conventional deep-drawing processes increase. The highof machine
number of
properties,
parameters parameterization
motivates the aim: of Athesystematic
movementdesign functions) in comparison
of deep-drawing to conventional
processes with free deep-drawing
force and motion processes increase.
functions Thepresses
on servo high number of
based on
Inparameters
today’s business
motivates environment,
aim: AInthe trend towards more product variety and customization is unbroken. Due to this on
development, thebased
need of
computational sciencethemethods. systematic
the contextdesign
of thisof deep-drawing
publication, processes
the determination withof free force
optimal and motion
parameters functions
(force and motion servo presses
functions) on
for a deep-
agile and process
drawing reconfigurable
computational science production
methods.
with superimposed In the systems
contextemerged
vibrations of
onthis toscrew
cope presses
publication,
servo with
thevarious
will beproducts
determination and product
of optimal
investigated. With thefamilies.
parameters
help of To and
(force design and
motion
evolutionary optimize production
functions)
optimization for a deep-
approaches
systems
drawing as well as
process with
a process-design to choose the
for asuperimposed optimal
deep-drawingvibrations product
process with matches,
on servo product
screw presses
superposition analysis methods
will be investigated.
of low-frequency are needed.
Withwill
oscillations Indeed,
the help most of
of evolutionary
be carry the knownof methods
optimization
out. The results aim to
approaches
the evolutionary
analyze a product
aoptimization
process-design or one product
for a deep-drawing
approaches family
are validatedprocess on the physical level.
with superposition
by experiments Different
with cross of product
dielow-frequency
part. families, however, may differ largely in terms of the number
oscillations will be carry out. The results of the evolutionary and
nature of components.
optimization approaches This
are fact impedes
validated an efficient with
by experiments comparison
cross dieand choice of appropriate product family combinations for the production
part.
system.
© 2021AThenewAuthors.
The methodology
Publishedis proposed
by Elsevier
Elsevierto analyze
B.V. existing products in view of their functional and physical architecture. The aim is to cluster
© 2021 Authors. Published by B.V.
these
©
This products
2021 The
is an inaccess
new assembly
Authors.
open Published
article oriented
underby product
Elsevier
the CC B.V.familieslicense
BY-NC-ND for the optimization of existing assembly lines and the creation of future reconfigurable
article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
(https://creativecommons.org/licenses/by-nc-nd/4.0)
assembly systems.
This is an open
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(http://creativecommons.org/licenses/by-nc-nd/4.0/)
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functional analysis is performed.
under responsibility of Moreover,
the scientific a hybrid
committeefunctional and CIRP
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Keywords:between product families by providing design support to both, production system planners and product designers. An illustrative
Keywords:
example of a nail-clipper
deep-drawing; is used optimization;
evolutionary process to explain the proposed
servo methodology.
screw press; An industrial
machine learning; case study onvariable
cushion-ram-pulsation; two product
stroke families of steering columns of
deep-drawing; Presta
thyssenkrupp evolutionary process
France is thenoptimization;
carried outservo screw
to give press;industrial
a first machine learning;
evaluationcushion-ram-pulsation; variable stroke
of the proposed approach.
© 2017 The Authors. Published by Elsevier B.V.
Peer-review
1. Motivationunder responsibility of the scientific committee of the 28th CIRP Design The paper examines
Conference the well documented part geometry of
2018.
1. Motivation theThe paper examines
symmetric cross cupthe forwell documented part
the deep-drawing geometry
process with su-of
FreelyAssembly;
Keywords: Design method;
programmable forceFamily
and identification
motion functions (e. g. the symmetric
perimposed cross cup
low-frequency for the deep-drawing
vibrations on a process
servo screw with su-
press,
[1, Freely
2]) on programmable
servo screw presses force extend
and motion functions
the forming (e. of
limits g. perimposed
investigated low-frequency vibrations on
in [2]. The experimental anda numerical
servo screw press,
research
[1, 2]) on servo screw presses extend
deep-drawing processes. [3] gives an exemplary overview of the forming limits of investigated
is done with inthe[2]. The
ordinary experimental
material DC01and numerical
(Nr. 1.0330 research
see EN
deep-drawing processes. [3] gives an exemplary overview of is done with
10130:2007-02) the ordinary
with a material
sheet DC01
thickness of (Nr.
1.16 1.0330
mm. see EN
1.possible
possible
applications. The variable processes have much more
Introduction
applications. The variable processes have much more of the product range
10130:2007-02) with and
a characteristics
sheet thickness of manufactured
1.16 mm. and/or
design parameters as the conventional deep drawing processes
design parameters as the conventional deep drawing processes assembled in this system. In this context, the main challenge in
with only one constant blankholder force. The requirements for
withDue to
only one the fast
constant development
blankholder in the domain of modelling
2. State ofand theanalysis
art is now not only to cope with single
a suitable process design increases force.
with the Thevariability
requirements for
and the 2. State of the art product range or existing product families,
communication
acomplexity. and an ongoing trend of
suitable process design increases with the variability and the digitization and products, a limited
digitalization,
complexity. manufacturing enterprises are facing important but With
also toservo
be able to analyze
presses, and to compare
productivity outside theproducts to define
workpiece con-
This motivates the central research question: How can the With servo presses,Itproductivity outside the workpiece con-
challenges in
This motivates today’s market
the central environments:
research question: aHow continuing
canvari-
the new
tact product
could be families.
significantly can be observed
increased by that
adjustingclassical
the ramexisting
speed.
development of complex deep-drawing processes with tact could be significantly increased by adjusting the ram speed.
tendency
development towards complex
reductiondeep-drawing
of product development with times and product families
The subject are regrouped
of current research in function of clients
is the analysis of or features.
freely pro-
able force andofmotion functions on servoprocesses screw presses vari- sys- The subject of current research is the analysis of freely pro-
shortened
able product
force and lifecycles.
motion In In
functions addition, there
on evolutionary is an increasing
servo screw optimization
presses sys- However,
grammable assembly
motion oriented
functions product
with families
closed are hardly
deep-drawing to find.
dies
tematically supported? this paper grammable motion functions with closed deep-drawing dies
demand
tematicallyof customization, being at the same time in a global in On the
workpieceproduct family
contact level,
during theproducts
forming differ mainly
process. The in two
appli-
methods aresupported?
proposed toIndetermine
this papersuitable
evolutionary
processoptimization
parameters, in workpiece contact during the forming process. The appli-
competition
methods with
areensure competitors
proposed to determineall over the world. This
suitable process parameters, trend, main
cation characteristics:
advantages of(i)
a the
highnumber of components
flexibility as well as and
high(ii) the
pro-
which will productive manufacturing. cation advantages of a high flexibility as wellelectronical).
as high pro-
which is inducing the development
which will ensure productive manufacturing. from macro to micro type of components (e.g. mechanical, electrical,
markets, results in diminished lot sizes due to augmenting Classical methodologies considering mainly single products
product varieties (high-volume
∗ Corresponding Author.
to low-volume production) [1]. or solitary, already existing product families analyze the
To∗ cope with
Corresponding this augmenting variety as well as to be able to product structure on a physical level (components level) which
2212-8271 © 2021Author.
The Authors. Published by Elsevier B.V.
identify
2212-8271
possible
© 2021
This is an open
optimization
Thearticle
access Authors. Published
under
potentials in
by Elsevier B.V.
the CC BY-NC-ND
the existing causes difficulties regarding an efficient definition and
license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
production
This is an open
Peer-review system,
underaccess it is important
article under
responsibility to have
CC BY-NC-ND
of the scientific a precise
license
committee knowledge comparison of different
System. product families. Addressing this
(http://creativecommons.org/licenses/by-nc-nd/4.0/)
of the 54th CIRP Conference on Manufacturing
Peer-review under responsibility of the scientific committee of the 54th CIRP Conference on Manufacturing System.
2212-8271 © 2021 The Authors. Published by Elsevier B.V.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-reviewunder
Peer-review under responsibility
responsibility of the
of the scientific
scientific committee
committee of theof28th
the CIRP
54th CIRP
DesignConference
Conferenceon Manufacturing System
2018.
10.1016/j.procir.2021.11.250
 Sebastian Kriechenbauer et al. / Procedia CIRP 104 (2021) 1482–1487
S. Kriechenbauer, P. Müller, R. Mauermann, W.-G. Drossel / Procedia CIRP 00 (2021) 000–000
ductivity of servo presses of different designs with adjusted
motion functions can be obtained from previous investigations
[4, 5, 6, 7, 2, 8, 3, 9].
2.1. Motion and force controlled drawing technologies
Fig. 1 shows different sets of motion functions used for deep-
drawing on servo presses with freely programmable motion
control. A set of motion function consists of the time sequences
of the rajectories of all active parts of the deep-drawing tool
(die, blank holder, drawing and counter-punch). For all forming
technologies in Fig. 1, with the exclusion of drawing technolo-
gie (d), the drawing punch is mounted on the press table.
Fig. 1. Examples of variable motion and force functions used for deep drawing
to extend process limits. Schematic diagrams for clarification purposes.
The forming technology in Fig. 1 (a) was used to investigate
the material behaviour during stroke interruption [10, 11]. In
further work, freely programmable motion functions as in Fig. 1
(b) were used to determine the friction between sheet metal and
tool [12]. The springback of an open profile could be reduced
by a return stroke at the end of the process as shown in Fig. 1
(c) [4].
Necking and wrinkling are the main failures in deep-
drawing. In order to effectively use the deformability of the
material, several approaches have been investigated so far. The
technologies (d .. f) in Fig. 1 have the aim of extending the
forming limits by superimposing vibrations during the forming
process.
The well-known technology of the pulsating die cushion [13]
increases the process reliability, the schematic motion functions
are shown in Fig. 1 (e). For hydraulic presses with servo valves
or servo pumps, a sinusoidal characteristic of the die cushion
1483
2
Fig. 2. Definition of wrinkles height
force can be programmed [14]. On presses of this type, force
and motion functions as shown in Fig. 1 (e) with oscillating
blankholder force in the low-frequency range at less than 50 Hz
were obtained.
2.2. Cushion-Ram-Pulsation
The development of highly dynamic servo press technology
(separate controllable drive axes, see [15]) permits the gener-
ation of active load changes through the synchronized motion
control of the individual drive units. Due to the high drive stiff-
ness of servo screw presses as well as the motion control of
ram and die cushion, technologically optimized motion func-
tions can be carried out with sufficient accuracy and dynamics
( f < 15 Hz) [1, 16]. This extended application potential is used
for the synchronized motion control of drawing cushion and
ram to reduce the stress in the frame. The drawing depth only
increases when the tool is opened.
In order to reduce the wrinkles height, shown in Fig. 2, the
drawing cushion is moved against the waiting ram so that the
drawing tool is closed under high force without increasing the
drawing depth. The part quality is affected by the opening of
the drawing tool in the flange area. Experimental investigations
have shown effects for the motion functions in Fig. 1 (f) which
lead to an extension of the forming limits [2]. The process is
described as ”Cushion-Ram-Pulsation” (CRP). Further research
is being carried out on CRP in press hardening [17].
3. Simulation and Experiment
The cross-cup geometry from Fig. 3 was choosen as ref-
erence design. With the process parameters of the simulation
model a deep-drawing depth of 60 mm is achieved. The in-
vestigated drawing process in Fig. 4 consists of two serial
forming technologies. Sequence one depicts the conventional
deep-drawing and sequence two the CRP technology. The con-
sideration of a subsequent third sequence (conventional Deep
Drawing, DD) could be excluded in preliminary investigations
due to the minor improvements compared to the reference de-
sign. The blankholder force Fbh in conventional deep-drawing
acts as a clamping force Fcl for the CRP sequence due to the in-
direct position control of the drives [18], with which wrinkling
can be limited.
1484 Sebastian Kriechenbauer et al. / Procedia CIRP 104 (2021) 1482–1487
S. Kriechenbauer, P. Müller, R. Mauermann, W.-G. Drossel / Procedia CIRP 00 (2021) 000–000 3

Fig. 3. Tool geometry used in cushion ram pulsation of a cross die Fig. 4. Motion and blankholder force of the investigated process

3.1. Experimental setup

The work of [15] specifies technical details of the used servo

screw press. Fig. 3 illustrates the blank outline (a) and the tool
geometry of the cross cup (b, c). For the following investiga-
tions, the drawing-die is coupled with the ram and the drawing
punch is mounted on the press table.
The Blankholder and the punch forces are measured by force
transducers with an accuracy class 1 mounted at the drawing
pins and at the drawing punch, respectively. The drawing force
is measured by the servo screw press itself [15].

3.2. Numerical reference

In this paper, LS-DYNA was used for the process simulation.

The process shown in Fig. 4 can be simulated with an advanced
finite element process model, which considers the elasto-static
properties of the servo screw press [19]. In previous studies, the
process model was validated by numerous experiments [1]. The
examined cross die is symmetric with respect to the xz and yz
planes. Assuming the wrinkling will also be symmetrical un-
der a centric load, the calculation effort can be reduced with
the process model visualized in Fig. 5. This includes the sheet
metal part and the top surfaces of the deep-drawing tool. Rigid
shell elements without thickness build the tool surfaces of die,
blankholder and drawing punch. Between the sheet metal part
and the tool, there is assumed a constant coefficient of friction
µ = 0.13 for the Coulomb friction model.
The blank consists of shell elements (Belytschko Lin-Tsay,
type 2 in LS-DYNA). The calculation is performed with 1 inte-
gration point in the shell plane and 10 integration points over
the shell thickness, which is initially 1.16 mm. The elastic-
plastic, anisotropic behavior of the investigated material is rep-
resented by the flow curve Cy (Cφ + φ)n in the material model
Fig. 5. Advanced finite element model of the symmetrical cross die considering
the vertical stiffness of the servo screw drives
MAT BARLAT YLD2000 in LS-DYNA with the parameters in
Tab. 1. The x axis determines the referenced rolling direction as
shown in Fig. 3a. Three r-values are needed for the calculation
of the material anisotropy.
Due to the local bending during formation of wrinkles in
the flange, infinitesimal material elements close to the surface
will change alternately between tension and compression loads.
Therefore, the Bauschinger effect is considered in the form of a
single parameter β = 0.36 in the material model. The elements
in the sheet metal are approx. 4.0 mm by 4.0 mm at the be-
ginning of the simulation. During the simulation, the elements
are locally refined with an h-adaptive algorithm. For example,
the element size decreases to 0.5 mm by 0.5 mm. As a result,
smaller wrinkles are formed at a higher level of resolution. At
 Sebastian Kriechenbauer et al. / Procedia CIRP 104 (2021) 1482–1487 1485
S. Kriechenbauer, P. Müller, R. Mauermann, W.-G. Drossel / Procedia CIRP 00 (2021) 000–000 4

Table 1. Material parameters for DC01 described by MAT BARLAT YLD2000

in LS-DYNA and further parameters of the advanced model

Parameter Value Unit

elastic modulus E 191.6 GPa

density ρ 7.8 × 10−9
poissons ratio ν 0.3
bauschinger β 0.36
anisotropy r0 1.181
anisotropy r45 0.920
anisotropy r90 1.458 Fig. 6. Flowchart of the investigated optimization problem
barlat exponent a 6.0
In order to keep the total time of the whole drawing process
stress constant Cy 569.68 MPa as short as possible, a partial application of CRP as shown in
strain constant Cφ 0.01 Fig. 4 with appropriate amplitudes is aimed for. Keep in mind,
yield exponent n 0.17 that small amplitudes extend the whole process time. A high
preload force can help to reach a better part quality with smaller
stiffness ram cra 557 (up to 100 kN) kN/mm wrinkles in the flange [1].
1969 The complex objective conflict can be solved by an opti-
stiffness cushion ccu 1738 kN/mm mization algorithm as shown in Fig. 6 based on an evolution-
ary strategy with hybrid crossover and self adaptive mutation.
In this paper, the optimization was calculated with OptiSLang.
The paper [21] discusses many combinations of genetic opera-
the beginning of the CRP process, the blankholder force (Fbh ) tors for different test functions. The choosen strategy is suitable
clamps tool parts against each other. This defines an ideal start- to overcome local minima.
ing point for the path functions of CRP. Since the process is A good starting point for the optimization is the field meta-
controlled by motion, the blankholder force raises indirectly up, model [22] obtained from the sensitivity analysis. This allows
when the blankholder approaches the die as shown in Fig. 4. to globally select only the important process parameters and
The resulting blankholder force at the end of the CRP process objective functions in the evaluated design space. Often the op-
will be always higher than the initial force due to the wrinkling. timization task is quite complex and nonlinear. Improvements
In order to realistically reproduce the wrinkle formation in will be found with a global search in the design space as pro-
the CRP process, in the advanced forming process model [19] vided by evolutionary optimization algorithms [21].
a vertical one-dimensional spring stiffness must be considered Multi criteria optimization tasks create a set of pareto solu-
for the drive system of the ram and the cushion. The model is tions [20, p. 31], from which the optimal design is selected with
based on the measurements described in [15]. the engineer’s point of view.

4.2. Definition of the optimization task

4. Pareto optimization using evolutionary strategy
The focus of the optimization is to reduce the process time
4.1. Conflicting objectives in deep drawing processes with T tot . Thereby the wrinkle height (see ∆h in Fig. 2) and the max-
CRP and their solution imum sheet thinning ∆sr,max in the crack critical area should be
as small as possible. The following functions can be defined.
Several objectives are pursued in the optimization of the f1 (X) = min{T tot }, (1)
X
CRP process. The main objective is to shorten the process time,
e.g. by increasing the ram amplitude. However, large ampli- f2 (X) = min{∆h} und (2)
X
tudes of ram (see Fig. 4, zra ) cause a strong wrinkle formation  s0 − s 
in the flange of the drawing part. The excessive wrinkling re- f3 (X) = min ∆sr,max = (3)
duces the part quality. Further goals are to minimize wrinkles
X s0
and sheet thinning. As a secondary condition it is required that As an additional boundary condition the crack critical thinning
the thinning of the sheet metal must not exceed 25 %. Due to ∆sr,crit of 25 % is specified.
the conflicting goals of process time and wrinkle formation, the g(X) ≤ ∆sr,crit (4)
best possible designs are on the Pareto front [20, p. 31]. For
this optimization problem, the Pareto front is described by a During the multi-criteria optimization, different designs for the
three-dimensional surface. The selection of an optimal design parameter vector X are generated and calculated within the pa-
is based on engineering criteria, such as a stronger weighting of rameter limits (range).
the process time. X = (∆zd Fbh zra zcu )T (5)
1486 Sebastian Kriechenbauer et al. / Procedia CIRP 104 (2021) 1482–1487
S. Kriechenbauer, P. Müller, R. Mauermann, W.-G. Drossel / Procedia CIRP 00 (2021) 000–000 5

Table 2. Design parameters and results of evolutionary optimization

Parameter Range Reference Design1 Design2 Design3 Unit

drawing depth ∆zd 0 .. 60 0 5.0 6.5 6.2 mm

blank holder force Fbh 50 .. 500 400 368.6 341.4 459.3 kN
stroke of ram zra 0.5 .. 5.0 0.4 0.6 0.6 1.0 mm
stroke of cushion zcu 0.3 .. 3.0 2.5 2.8 0.8 2.2 mm
process time T tot 47.62 32.27 20.81 17.31 s
(-32.2 %) (-56.3 %) (-63.6 %)
wrinkle height ∆h 0.19 0.18 0.18 0.19 mm
(-5.3 %) (-5.3 %) (0 %)
sheet thinning ∆sr,max 16.38 16.38 18.97 18.97 %
(0 %) (+15.8 %) (+15.8 %)

In this paper, 470 designs were generated by latin hyber-

cupe sampling to properly calculate the field metamodel. Many
designs fail due to the restrictive constraints. The optimization
starts with 53 feasible designs from the metamodel and 168 fea-
sible designs calculated by the optimization algorithm, which
stopped at the maximum of 200 calculated designs. This are 20
generations with a population size of 10. The hybrid crossover
includes the multipoint method with 3 points and the simulated
binary method with a crossover probability of 50 % and a dis-
tribution parameter of 2. The self adaptive mutation uses a mu-
tation rate of 16 %. The optimization task can run on a common
workstation in few days.

4.3. Results

Three optimized designs were selected on the calculated

pareto front. The values of the parameters are printed in 2. In
this paper, the wrinkle height and the thickness of the deep
drawn parts were measured with GOM ATOS. The measure-
ments are visualized in Fig. 7.
The optimized process design 3 needs exactly 17.31 s for
the whole process. This corresponds to a time saving of 63.6
% compared to the reference process with 47.62 s. The ref-
erence design was choosen from numerous experiments [1],
which have small wrinkles. In addition, further investigations
onto the field metamodel leads to a proper decision. Neverthe-
less, the process times for deep drawing with CRP are quite
long and can only be reduced by an optimzation calculation.
The blankkholder force Fbh from the forming operation DD
acts in the CRP process as a clamping force Fcl. This can
limit the formation of wrinkles as described in [1]. However, Fig. 7. Measured Wrinkling and Thickness Distribution of the referenced and
the comparison between the measured results (a) and (b) in 7 optimized deep drawn Parts
shows, that the wrinkle height cannot be reduced in the con-
sidered design space (range of values in Tab. 2). The minimal
sheet thickness decreases slightly with the optimized process which leads to shorter process time compared to the reference
parameters, but remains below the defined thinning of 25 % design. Small amplitudes should promise small wrinkles, but
for cracks. cause long running processes.
The cross cups in Fig. 7 (d) and (c) are very similiar. The Fig. 2 visualizes the detection of the wrinkle height. In
The evolutionary optimization found suitable CRP parameters, the experiment the wrinkles can only be measured on the sheet
 Sebastian Kriechenbauer et al. / Procedia CIRP 104 (2021) 1482–1487
S. Kriechenbauer, P. Müller, R. Mauermann, W.-G. Drossel / Procedia CIRP 00 (2021) 000–000
metal part outside of the deep drawing tool e. g. with GOM
ATOS. This global measurement method affects the proposed
wrinkle height due to the springback of the released part. That
is why the wrinkle height defined in Fig. 2 is measured as objec-
tive inside the closed tool at the end of the process simulation.
5. Conclusion
The described example shows, how the evolutionary opti-
mization can provide an optimal solution for the complex deep
drawing processes with freely programmable force and motion
functions. The method is a suitable tool for the development of
deep drawing processes with superimposed low-frequency vi-
brations on a servo screw press.
The process simulation must be accurate inside the design
space based on the advanced forming process simulation [19].
This approach is very efficient to run many simulations. Any
sheet metal forming processes on servo presses can also be an-
alyzed with the proposed evolutionary optimization procedure
as well.
The model must include all relevant influences inside the de-
sign space. Therefore, a sensitivity analysis of the investigated
process is carried out beforehand. This task sharpens the under-
standing of the process and improves the simulation.
Future research tasks will further deal with freely pro-
grammable motion and force functions in deep drawing. The
process development will then take place on the basis of the
desired component geometry within the scope of the capabili-
ties of the given servo press. This will improve the application
potential of the servo presses.
Acknowledgements
The presented results are part of public research projects
at Fraunhofer Institute for Machine Tools and Forming Tech-
nology IWU, which is located in Chemnitz, Germany. The
Projects 17058BR, 17488BR and 19007BR of the research as-
sociation Europäische Forschungsvereinigung für Blechverar-
beitung e. V. (EFB) were financed by the Arbeitsgemeinschaft
industrieller Forschungsvereinigungen Otto von Guericke e. V.
(AiF) as part of the program to support Industrial Community
Research and Development (IGF) with funds from the Federal
Ministry for Economic Affairs and Energy (BMWi) following
an order by the German Federal Parliament. Further develop-
ment and practical work were funded by the Federal Ministry
of Education and Research (BMBF) as part of the reasearch
project ML@KaroProd. The financial support and cowork are
gratefully acknowledged by the authors.
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