Curating Datasets of Flexible Assemblies to Predict Spring-Back Behavior for Machine Learning Purposes

Alex Adrian, Satchit Ramnath, Sai Chandu Sunkara, Y. Korkolis, J. Davidson, J. Shah
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Abstract

There are many sources of manufacturing variations in sheet metal assemblies, such as automotive bodies. These include non-isotropic material properties from cold rolling, springback in stamping, and distortion from residual stresses when components are clamped and spot welded. FE simulations have been used to predict these variations in order to better design tooling and processes. Such simulations require expertise in complex, multi-stage nonlinear analysis. We are investigating the feasibility of training machine learning algorithms in order to democratize these types of analyses. This requires the curation of large, validated, and balanced data sets. To this end, we have developed a multi-stage finite element simulation workflow encompassing component stamping and joining with a focus on examining deformations due to springback in two-part assemblies. Three connected simulations comprise the workflow: (1) component stamping with capture of springback, (2) assembly clamping, and (3) assembly joining, then release. The workflow utilizes explicit dynamic finite element analysis (FEA) and includes the transfer of intermediate solutions (geometries/stresses), as well as extraction of key geometric parameters of springback from both component- and assembly-level simulations. The NUMISHEET 1993 U-draw/bending benchmark was referenced for its tooling geometry and utilized for verification of the forming process simulation; variations of material and geometry were also simulated. In summary, this work provides a means of generating a design space of flexible two-part assemblies for applications such as dataset generation, design optimization, and machine learning.
基于机器学习目的的柔性组件数据集预测回弹行为
在钣金组件中有许多制造变化的来源,例如汽车车身。这些包括冷轧时的非各向同性材料特性,冲压时的回弹,以及零件夹紧和点焊时的残余应力造成的变形。有限元模拟已用于预测这些变化,以便更好地设计工具和工艺。这样的模拟需要复杂的、多阶段的非线性分析方面的专业知识。我们正在研究训练机器学习算法的可行性,以便使这些类型的分析大众化。这就需要管理大型的、经过验证的、平衡的数据集。为此,我们开发了一个多阶段的有限元模拟工作流程,包括组件冲压和连接,重点是检查两部分组件中由于回弹引起的变形。三个连接的模拟包括工作流程:(1)组件冲压与回弹捕获,(2)装配夹紧,(3)装配连接,然后释放。该工作流程利用明确的动态有限元分析(FEA),包括中间解决方案(几何形状/应力)的传递,以及从组件和装配级模拟中提取回弹的关键几何参数。参考NUMISHEET 1993 u -拉伸/弯曲基准的模具几何形状,并用于成形过程仿真的验证;材料和几何形状的变化也进行了模拟。总之,这项工作提供了一种为数据集生成、设计优化和机器学习等应用生成灵活的两部分组件的设计空间的方法。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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