Optimization of Forming Process Parameters for Automotive Advanced High Strength Steel Parts Using the Taguchi Method

Abstract

This paper presents a comparative analysis between finite element simulation results and actual formed parts, utilizing different material model combinations. The Bow-RF panel part made from JSC980Y advanced high strength steel was chosen as a case study and investigated by using the finite element method (FEM). The comparison revealed that the combination of the Barlat 1989 yield criterion and the Yoshida-Uemori hardening rule in the finite element simulation gave the best predicted result of the panel part during the drawing process. This combination achieved the highest percentage of area in the displacement range of -1 to 1 mm (approximately 83.17%). Subsequently, Taguchi's Design of Experiments (DOE) and Analysis of Variance (ANOVA) were employed to analyze the influence of each process parameter on the simulation results, including blank holder force, die gap, and blank width. Finally, a statistical mathematical model was created using regression analysis. The results indicated that the most influential parameters, in decreasing order of significance, were die gap, blank holder force, and blank width. The optimal process parameters for achieving the highest percentage of area in the displacement range within -1 to 1 mm were determined to be a blank holder force of 41.21 tons, a die gap of 0.9 mm, and a blank width of 297.47 mm.