EXPLORING THE POTENTIAL FOR A FEA-BASED DESIGN OF EXPERIMENTS TO DEVELOP DESIGN TOOLS FOR BULK-METAL JOINING PROCESSES

Proceedings of the Design Society Pub Date : 2023-06-19 DOI:10.1017/pds.2023.182

Jacob Hatherell, Arnaud Marmier, G. Dennis, Will Curry, J. Matthews

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引用次数: 1

Abstract

Abstract Over the last 20 years, finite element analysis (FEA) has become a standard analysis tool for metal joining processes. When FEA tools are combined with design of experiments (DOE) methodologies, academic research has shown the potential for virtual DOE to allow for the rapid analysis of manufacturing parameters and their influence on final formed products. However, within the domain of bulk-metal joining, FEA tools are rarely used in industrial applications and limit DOE trails to physical testing which are therefore constrained by financial costs and time. This research explores the suitability of an FEA-based DOE to predict the complex behaviour during bulk-metal joining processes through a case study on the staking of spherical bearings. For the two DOE outputs of pushout strength and post-stake torque, the FEA-based DOE error did not exceed ±1.2% and ± 1.5 Nm respectively which far surpasses what was previously capable from analytically derived closed-form solutions. The outcomes of this case study demonstration the potential for FEA-based DOE to provide an inexpensive, methodical, and scalable solution for modelling bulk-metal joining process

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探索基于fea的实验设计的潜力，以开发大块金属连接工艺的设计工具

在过去的20年中，有限元分析(FEA)已成为金属连接过程的标准分析工具。当FEA工具与实验设计(DOE)方法相结合时，学术研究表明虚拟DOE具有潜力，可以快速分析制造参数及其对最终成型产品的影响。然而，在大块金属连接领域，FEA工具很少用于工业应用，并且将DOE跟踪限制在物理测试中，因此受到财务成本和时间的限制。本研究通过对球面轴承搭接的案例研究，探讨了基于有限元的DOE在预测大块金属连接过程中复杂行为的适用性。对于推力强度和桩后扭矩两个DOE输出，基于有限元的DOE误差分别不超过±1.2%和±1.5 Nm，远远超过了以前解析导出的闭型解的能力。本案例研究的结果表明，基于有限元分析的DOE为模拟大块金属连接过程提供了一种廉价、有条不紊、可扩展的解决方案

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Proceedings of the Design Society

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