Sensitivity analysis of near solidus forming (NSF) process with digital twin using Taguchi approach

IF 4.2 2区工程技术 Q2 ENGINEERING, MANUFACTURING Advances in Manufacturing Pub Date : 2024-04-03 DOI:10.1007/s40436-024-00482-4

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Abstract

Forging at near solidus material state takes advantage of the high ductility of the material at the semi solid or soft-solid state while keeping most of the mechanical properties of a forged part. The technology is at maturity level ready for its industrial implementation. However, to implement the process for complex cases the development of an appropriate digital twin (DT) is necessary. While developing a material model, a strong experimental and DT is necessary to be able to evaluate the accuracy of the model. Aimed at having a reliable DT under control, for future material model validations, the main objective of this work is to develop a sensitivity analysis of three NSF industrial cases such as Hook, R spindle and H spindle to develop an adequate DT calibration procedure. Firstly, the benchmark experimentation process parameter noise and experimentation boundary conditions (BCs) parameter uncertainty are identified. Secondly, the three industrial benchmark DTs are constructed, and a Taguchi design of experiments (DoEs) methodology is put in place to develop the sensitivity analysis. Finally, after simulations the results are critically evaluated and the sensitivity of each benchmark to the different inputs (process parameter noise and BC parameter uncertainty) is studied. Lastly, the optimum DT calibration procedure is developed. Overall, the results stated the minimum impact of the material model in terms of dies filling. Nevertheless, even if the material model is the highest impacting factor for the forging forces other inputs, such as heat transfer and friction must be under control first.

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利用田口方法对采用数字孪生的近固态成形（NSF）工艺进行灵敏度分析

摘要近固态材料锻造利用了半固态或软固态材料的高延展性，同时保持了锻件的大部分机械性能。该技术已达到成熟水平，可用于工业生产。然而，要在复杂情况下实施该工艺，必须开发适当的数字孪生（DT）。在开发材料模型的同时，还需要强大的实验和 DT 来评估模型的准确性。为了控制可靠的 DT，以便将来验证材料模型，这项工作的主要目标是对三个 NSF 工业案例（如 Hook、R 型主轴和 H 型主轴）进行敏感性分析，以开发适当的 DT 校准程序。首先，确定基准实验过程参数噪声和实验边界条件（BCs）参数不确定性。其次，构建三个工业基准 DT，并采用田口实验设计（DoEs）方法进行灵敏度分析。最后，对模拟结果进行严格评估，研究每个基准对不同输入（工艺参数噪声和 BC 参数不确定性）的敏感性。最后，制定了最佳 DT 校准程序。总体而言，结果表明材料模型对模具填充的影响最小。不过，即使材料模型是对锻造力影响最大的因素，也必须首先控制其他输入因素，如传热和摩擦。

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来源期刊

Advances in Manufacturing Materials Science-Polymers and Plastics

CiteScore

9.10

自引率

3.80%

发文量

274

期刊介绍： As an innovative, fundamental and scientific journal, Advances in Manufacturing aims to describe the latest regional and global research results and forefront developments in advanced manufacturing field. As such, it serves as an international platform for academic exchange between experts, scholars and researchers in this field. All articles in Advances in Manufacturing are peer reviewed. Respected scholars from the fields of advanced manufacturing fields will be invited to write some comments. We also encourage and give priority to research papers that have made major breakthroughs or innovations in the fundamental theory. The targeted fields include: manufacturing automation, mechatronics and robotics, precision manufacturing and control, micro-nano-manufacturing, green manufacturing, design in manufacturing, metallic and nonmetallic materials in manufacturing, metallurgical process, etc. The forms of articles include (but not limited to): academic articles, research reports, and general reviews.